Reciprocating Block Lead Delivery Apparatus for Battery Casting
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Solution Overview
Problem
In the manufacturing of batteries, particularly lead acid batteries, there is a challenge in ensuring consistent delivery of a predetermined volume of molten lead to mould cavities while minimizing cooling and maintaining unimpeded access for battery plates, as excess lead can impact cost and weight, and existing methods suffer from heat loss and dross formation.
Innovation Solution
An apparatus featuring a housing with a molten lead reservoir, a block with a through cavity for precise volume delivery, and a mechanism for reciprocating the block between positions, along with a chute for smooth lead flow, minimizes heat loss and dross formation by using an inert gas to prevent oxidation and includes a sump to collect excess lead, ensuring accurate and consistent lead delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lead is allowed to flow into channels at the sides of the mould cavity and spill over a weir, then the mould cavity can be filled with lead, but excess lead is used which increases cost and weight
Solution Approach 1:
The lead delivery system is segmented into a reservoir, a controlled delivery channel with a block, and a mould cavity. The block divides the flow path to precisely control the volume of lead entering the mould, preventing uncontrolled overflow and excess lead usage.
Solution Approach 2:
The invention changes the delivery parameter from uncontrolled flow to controlled volume delivery. By using a block with specific dimensions and positioning, the volume of lead delivered is precisely controlled to match the mould cavity requirements, eliminating excess lead.
2Reliability
If lead is kept hot to ensure good connection between lugs and casting, then connection quality is improved, but heat loss occurs during transit and production cycle time increases
Solution Approach 1:
The lead is rapidly transferred from the reservoir through the block delivery system directly into the mould cavity. This quick passage minimizes the time lead is exposed to ambient conditions, reducing heat loss while maintaining connection quality through controlled delivery.
Solution Approach 2:
The block acts as an intermediary between the reservoir and mould cavity. It controls the lead flow to ensure proper filling while minimizing exposure time, thus reducing heat loss. The block also helps direct lead flow to optimize connection formation.
3Quantity of substance
If a traditional mould filling system is used, then lead can be delivered to the mould, but access to the mould by plates may be impeded and cycle time increases
Solution Approach 1:
The block is designed to be movable or adjustable, allowing dynamic control of the delivery channel. This enables rapid opening and closing of the lead flow path, facilitating quick delivery and rapid ejection, thus reducing cycle time and improving productivity.
Solution Approach 2:
The block delivery system extracts only the necessary volume of lead from the reservoir and delivers it precisely to the mould cavity. This eliminates the need for excess lead and simplifies the delivery mechanism, reducing cycle time while maintaining production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus ensures precise, consistent delivery of molten lead with minimal heat loss and reduced dross formation, enhancing the efficiency and accuracy of lead casting while maintaining the required volume, thus optimizing battery production by reducing costs and weight.
Implementation Method 1
a block slidably mounted between the reservoir base and the runway, the block defining a through cavity having the predetermined volume for receiving lead from the outlet in a first position and for releasing the lead in a second position
Implementation Method 2
minimizing cooling and maintaining unimpeded access for battery plates, as excess lead can impact cost and weight, and existing methods suffer from heat loss and dross formation
Implementation Method 3
the apparatus may also ensure that the lead can be delivered from the reservoir with minimal heat loss
Implementation Method 4
includes a sump to collect excess lead
Data Source
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AI summary
An apparatus (5) for delivering a predetermined volume of lead to a mould (50) includes a housing (2) defining a lead reservoir (4) having a lead outlet defined in its base and in communication with the reservoir. A runway (30) is provided beneath the base, spaced from the base and generally parallel thereto. A block (10) is provided slidably mounted between the base and the runway and defining a through cavity (12) having the predetermined volume for receiving lead from the outlet in a first position and for releasing the lead in a second position. A mechanism (20) is provided for reciprocating the block (10) between the first and second positions. A cast on strap machine (1) is also disclosed. A lead delivery apparatus (5) comprising a delivery chute (40) is also disclosed.