Accumulator Treatment Plant With X-Ray Battery Sorting

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Solution Overview

Problem

The risk of explosions and chemical hazards in lead-acid accumulator treatment plants due to the presence of lithium-ion batteries, which are not easily distinguishable from lead-acid accumulators and can retain electric charge, leading to potential short circuits during grinding.

Innovation Solution

A treatment plant and process that uses an X-ray detector and processor to identify non-lead-acid accumulators before they enter the grinding mill, ensuring only lead-acid accumulators are processed, thereby preventing explosions and chemical risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual sorting by operators is used to separate lead-acid accumulators from other battery types, then sorting can be performed without advanced equipment, but the sorting is error-prone and cannot reliably distinguish between visually similar lithium-ion accumulators and lead-acid accumulators

Engineering Contradiction:

Improvesimplicity of sorting methodVSAvoidsorting accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical sorting by operators with an automated X-ray detection system. The X-ray detector captures images of batteries, and image processing algorithms automatically identify and classify battery types based on internal structure characteristics, eliminating human error while maintaining operational simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces X-ray imaging as an intermediary between the batteries and the sorting decision. The X-ray images reveal internal structural differences (lead grids in lead-acid accumulators versus aluminum foil in lithium-ion batteries) that are not visible externally, enabling accurate classification without direct manual inspection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If lithium-ion accumulators are processed in the grinding mill along with lead-acid accumulators, then all collected batteries can be treated uniformly, but explosions occur due to short circuits in charged lithium-ion batteries during grinding

Engineering Contradiction:

Improvethroughput of treatment plantVSAvoidexplosion risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent performs preliminary classification of batteries using X-ray detection before they enter the grinding mill. Lead-acid accumulators are identified by their characteristic lead grid structure and separated from lithium-ion batteries, ensuring that only suitable batteries are processed in the mill, thus preventing explosions while maintaining high throughput.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts lithium-ion batteries from the mixed battery stream before processing. By identifying and removing batteries with aluminum foil structures (lithium-ion) from those with lead grid structures (lead-acid), the system eliminates the explosion hazard while allowing continuous processing of safe batteries.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If X-ray detection is implemented to identify and separate non-lead-acid accumulators before grinding, then safety is significantly improved by preventing explosions, but the device complexity and cost increase due to addition of X-ray detectors and image processing systems

Engineering Contradiction:

Improvesafety of treatment processVSAvoidcomplexity of sorting system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex manual inspection procedures with automated X-ray imaging and digital image processing. The system captures X-ray images, processes them through algorithms that identify battery type based on internal structure, and automatically directs batteries to appropriate processing streams, achieving high reliability with manageable system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution significantly reduces the likelihood of non-lead-acid accumulators reaching the grinding mill, enhancing safety by accurately distinguishing between lead-acid and lithium-ion batteries, thus minimizing the risk of explosions and chemical exposure.

Implementation Method 1

The sorting device comprises an X-ray detector configured to perform an X-ray scan of the plurality of objects

Methodology Applied

Scientific EffectX-ray scan: X-Ray

Data Source

PatentUS12191463B2Spent or decommissioned accumulator treatment plant and process

Publication Date: 2025.01.07 ENGITEC TECHNOLOGIES SPA

AI summary

A spent and/or decommissioned accumulator treatment plant and process, wherein a plurality of objects originating from separate waste collection of spent and/or decommissioned accumulators, nominally comprising lead-acid accumulators and accumulators and objects of a different type, are subject to an X-ray scan. If an analysis of the X-ray scan indicates that an object is not a lead-acid accumulator, and in particular is a lithium-ion battery or accumulator, it is deviated out of the treatment workflow, that comprises grinding the objects and separating lead from other materials.