Rotatable Lead Bath Carriages for AGM and Wet-Cell Battery Production
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Solution Overview
Problem
Existing battery production installations are limited to processing only one battery type, requiring downtime for changes and struggling with different lead compositions, battery plate sizes, and dimensions, especially when producing AGM and wet-cell batteries for both passenger-car and commercial-vehicle sectors.
Innovation Solution
The installation features a centrally arranged rotatable transport apparatus, two heatable and movable lead bath carriages for quick lead bath changes, a gripper system with pneumatic cylinders for positioning battery plate packs, and a central control unit with adaptable processing sequences, allowing for the production of multiple battery sizes and types, including AGM and wet-cell batteries, with reduced cycle times and simplified changeovers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single battery type is processed in the installation, then the processing sequence and parameters can be optimized for that specific type, but the installation requires downtime for changing lead baths and cannot handle different battery types simultaneously
Solution Approach 1:
The lead bath system is segmented into multiple independent lead baths (first lead bath and second lead bath), each capable of holding different lead compositions. This allows the installation to process different battery types simultaneously without requiring complete shutdown for changes.
Solution Approach 2:
The lead baths are designed to be movable and exchangeable during operation. The system can dynamically switch between different lead baths based on the battery type being processed, enabling flexible production sequences without fixed assignments.
2Adaptability or versatility
If the lead bath is changed during production, then different lead compositions can be used for different battery types, but the installation must be brought to a standstill
Solution Approach 1:
Multiple lead baths are prepared in advance with different lead compositions suitable for different battery types. When a changeover is needed, the system can switch to a pre-prepared lead bath without requiring time for melting or composition changes, thus eliminating downtime.
Solution Approach 2:
The system can discard the current lead bath and recover/reuse the alternative lead bath that is already prepared. This allows rapid switching between lead compositions without the time-consuming process of melting down or reconfiguring the lead bath system.
3Adaptability or versatility
If different battery plate sizes and dimensions are handled, then multiple battery types can be produced, but additional tool parts and complex handling mechanisms are required
Solution Approach 1:
The clamping cartridges are designed with universal features that allow them to handle different battery plate sizes and dimensions through adjustable mechanisms. The same basic cartridge structure can accommodate various battery types without requiring completely different tooling for each size.
Solution Approach 2:
The handling system can adjust parameters such as clamping force, gripper position, and carriage dimensions to accommodate different battery plate sizes. This parametric adjustability allows a single system to handle multiple battery types without adding complex dedicated mechanisms for each size.
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
Enables efficient production of multiple battery sizes and types with reduced changeover times, increased installation utilization, and cost savings by maintaining a constant lead bath temperature and eliminating the need for additional tool parts, while ensuring reliable boxing of battery packs in varying dimensions.
Implementation Method 1
lead melting pot (3.1) for lead bath changing in the hot melted state
Implementation Method 2
pumping/suction apparatus (3.4) with lifting function which serves for lead bath changing
Implementation Method 3
pumping/suction apparatus (3.4) with lifting function which serves for lead bath changing
Data Source
AI summary
An installation for producing batteries is disclosed, having a lead bath station with two heatable and mobile lead bath carriages arranged in an assignable manner at the stationary lead melting pot. Both carriages having a pumping-sucking device that serves for the changing of the lead bath. Molten lead is pumped out of the lead pot into an empty carriage. Both the pumping-sucking devices are arranged pivotably about the axis of rotation (B) and the pivot pin that is fixedly arranged on the carriage is arranged such that it can be separately pivoted about the axis of rotation (A), thus, making it possible for the suction tube and a discharge tube to be moved between the carriage and the led pot.