Suction System for Lead-Acid Battery Formation Plant

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The industrial production of lead-acid batteries faces issues with organic material additives forming lumps in the electrolyte solution, which can clog inlet ducts, leading to overheating and damage of cells, requiring costly and inefficient manual intervention for clearance.

Innovation Solution

A plant and process for electrochemical formation of lead-acid batteries that includes a suction system to automatically clear lumps from inlet ducts, ensuring continuous electrolyte flow and preventing clogging, with a distribution manifold and collection manifold system that maintains controlled pressure and flow rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If organic material additives are inserted in the active material to increase contact surface area, then the charging efficiency is improved, but lumps form in the electrolyte solution that can clog inlet ducts

Engineering Contradiction:

Improvecharging efficiencyVSAvoidinlet duct clogging

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A suction system acts as an intermediary mechanism between the electrolyte circulation system and the inlet ducts. This suction system continuously or periodically removes lumps of organic material from the electrolyte solution before they can clog the inlet ducts, thereby maintaining both charging efficiency and system reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The suction system performs preliminary removal of lumps from the electrolyte solution before the solution reaches the inlet ducts. By proactively removing potential clogging agents in advance, the system prevents clogging rather than reacting to it after occurrence

Inventive Principle:

Principle #10Preliminary action

2Reliability

If manual intervention is used to clear clogged inlet ducts, then the clogging problem is resolved, but production efficiency decreases and specialized personnel are required

Engineering Contradiction:

Improveinlet duct clearanceVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The suction system enables the electrolyte circulation system to self-maintain by automatically removing lumps from the inlet ducts without requiring manual intervention. This self-service capability maintains reliability while preserving production efficiency and eliminating the need for specialized personnel

Inventive Principle:

Principle #25Self-service

3Productivity

If high currents are applied to accelerate battery formation, then the formation time is reduced, but the temperature of electrodes and electrolyte increases

Engineering Contradiction:

Improveformation timeVSAvoidelectrode and electrolyte temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The suction system operates continuously or periodically throughout the high-current formation process to remove lumps that could cause clogging. This continuous maintenance enables uninterrupted high-current operation, maximizing formation speed while preventing temperature-related failures through reliable duct operation

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The suction system provides a feedback mechanism that monitors and responds to the formation process conditions. By continuously removing lumps, it maintains optimal flow conditions that enable sustained high-current operation, creating a feedback loop that supports accelerated formation

Inventive Principle:

Principle #23Feedback

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

Ensures all cells receive a consistent flow of electrolyte solution, preventing overheating and damage, and allows for fully automatic operation without specialized personnel, enhancing efficiency and reliability.

Implementation Method 1

a suction system to automatically clear lumps from inlet ducts

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 2

its temperature characteristics are controlled with a heat exchanger

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 3

the electrochemical reactions occur for the transformation of chemical energy into electrical energy and vice versa

Methodology Applied

Scientific EffectElectrochemical reaction:

Implementation Method 4

the ohmic effect arising from the passage of the direct current

Methodology Applied

Scientific EffectOhmic heating: Joule Heating

Data Source

PatentUS9812737B2Plant and process for the electrochemical formation of lead-acid batteries

Publication Date: 2017.11.07 SOVEMA

AI summary

Plant for the electrochemical formation of lead-acid batteries, which comprises an external circuit (5) in which an electrolytic solution flows with controlled temperature; such solution traverses the single cells (2) provided with metering caps (17) provided with an inlet duct (18) connected with a first connector to a distribution manifold (9) of the circuit and with an outlet duct connected with a second connector to return means (7) of the circuit. The plant also comprises suction means connected to the distribution manifold (9) and actuatable to suck, with the feeding to the distribution manifold (9) interrupted, the electrolytic solution contained in the distribution manifold (9) as well as possible lumps therewith that have stopped in the inlet ducts and/or in the first connectors for feeding the cells (2).