1. First of all, we should weigh the plates inside each battery, as well as group the plates. The capacity of each cluster should be equal, otherwise the small capacity of the group because of the small capacity will be fully charged in advance, then the capacity of the battery group is not yet full, the battery terminal voltage is low, the total voltage is not full of the termination voltage is still continuing to charge, resulting in the formation of the capacity of a small group of overcharging, if it is a small capacity of the group in the battery discharge in advance of the amount of electricity is not available, the other batteries with high terminal voltage, the total voltage is not electric boost termination protection voltage, discharge is still forming the overcharging, if it is a small capacity of the group is not available, other battery terminal voltage, the total voltage is not electric boost termination protection voltage. The total voltage does not have the termination protection voltage of the electric power assist, the discharge is still continuing, however, it causes the battery over-discharge. Battery overcharging and overdischarging as well as charging is not timely will affect the service life of the battery, however, the battery capacity of the small group of batteries to further decline in the capacity of the battery to further make the group of overcharging and overdischarging, and so on the cycle of the battery capacity will soon be reduced and scrapped.
The required equipment: weighing instrument, grouping machine, pole plate short circuit tester, pole plate welding mold, pole plate welding tools and so on.
2. In the weighing before the treatment of the pole plate
In the pole plate before weighing to clear the plate to delete the production of excess front edge, burr, in the coating of the paste excess active material, if not clean, it will cause the battery pole plate short-circuit battery self-discharge. To use the pole plate brush headset to brush the excess impurities on the pole plate to facilitate welding, in order to prevent the cause of false welding, false welding. To pick out the pole plate with unevenness, serious de-powdering, and holes in the pole plate.
Introduction of equipment needed: brush headset, etc..
3. How to weigh the pole plate
When the pole plate is weighed and assembled, a part of the pole plate should be weighed and discharged on the working table in sequence according to the different weights, than and mark the weights, and then weigh the pole plate that is not weighed and weigh the weight of each piece of the pole plate on the weighing instrument, and place the pole plate placed on the working table according to the weighed weights, which will save some trouble. (The smaller the weight difference between each group of positive or negative plates, the better, the error of 10-14AH should not be more than 1 gram per group, and the error of 17-20AH should not be more than 2 grams per group.
Introduction of equipment required: weighing instrument, molds, workbench and so on. 1. After weighing the pole plate in accordance with the provisions of the weight of the group, with a good group after the package plate, the material of the bulkhead of the general microporous rubber, fiberglass, in the package should pay attention to the cleanliness of the bulkhead, the pole plate to be placed in the middle of the bulkhead, if the pole plate position is aligned in the pole plate box.
2. Double-piece package positive plate, with very thin spacer piece together only the positive plate to hold up, do not wrap the negative plate, so that you can avoid the short circuit caused by defects in a single piece of spacer. Single-piece package board, with the spacer only on the positive plate packaging does not wrap the negative plate inside the package board box can be convenient and simple.
Introduction of equipment required: package board box, etc. 1. 1. Lead parts have lead welding rod and pole, there are special mold casting. Generally at about 450 ℃, the temperature is too high lead oxidation is serious, lead parts due to serious contraction caused by cracks, do not allow the use of iron to knock the mold. Do come out of the lead parts to try to ensure that there is no prickly edges around, if so, to be trimmed.
Introduction of equipment needed: welding pliers, welding molds, oxygen welding tools, lead furnace, etc.. 1. Cluster welding, welding is the positive and negative poles with lead welded together to form a cluster, in the pole and the busbar connected to the tool with oxygen - acetylene.
2. Put the wrapped pole plate in the cluster box, insert the pole plate in the cluster box into the comb plate, first insert the negative pole in the positive pole, so that the pole lugs are completely inserted into the comb plate. If it is not in place, organize it by hand, and then put the gear bar between the positive and negative pole lugs, the bridge post, and the pole post.
3. Turn on the welding torch acetylene and oxygen and ignite, adjust to the appropriate size. Welding gun and welding rod to move to the position of the pole ear, and then melt the lead and the pole ear, the busbar is basically welded, in the pole with the busbar welded together. If there are impurities such as lead ash during the welding process, we will find out the false welding and false welding. Welding the pole and the busbar is the key process in the production process, and we should make sure that the welding is firm and there is no false welding and false welding. At this time to be welded while the impurities to be removed, and finally fill the busbar.
Required equipment: busbar molds, soldering guns, cluster boxes and so on. 4. Welded bus, test no defects and then enter the process of loading groove, generally to be loaded first into the cluster with terminals, after loading in the loading of other clusters, the positive and negative poles are arranged as + -, + -, + -, + -, + -, + -, + -, + - in series, do not load the wrong polarity.
When the pole plate is installed in the slot, it must be installed to the bottom, and then in the detection of the bridge column is not normal, such as if there is a shift in the manual processing of good, in the trial installation of the top cover can be covered with the basic clusters under the slot has been completed.
5. How to check the cluster that, first of all, we use a multimeter to measure the battery has no short circuit, if the measured voltage is zero or close to zero to prove that the battery is short-circuited, check the cluster to find out the location of the short-circuit repair. Check that there is no short circuit in the case of the multimeter positive and negative poles connected is not the display of the voltage does not appear negative, if there is, prove that the polarity of the installation of the reverse, and then re-installed in the battery slot.
6. After the pole plate test no fault into the bridge welding, pole group welding is a key one. Use the bridge welding clamp to clamp the column, and use oxygen welding to weld the bridge column. In the welding flame to ensure that do not burn to the battery shell, to ensure that there is no false welding, false welding, pole columns out of the cluster, can close the cover smoothly. Battery cover sealing, with epoxy resin glue and curing agent with the use of 2:1 ratio comparison. Matching good glue should be used in time, so as not to long time solidification, gel solidification and temperature has a lot to do with the temperature, the higher the temperature solidification of the faster, so use as soon as possible. There is also heating equipment for capping.
7. After the battery capping is completed, we should carry out the pole welding, and test whether the pole is in the center of the lead hole, if not, we should make corrections. In the pole mold set in the lead out of the pole on the pole and then use oxygen welding to melt the pole. There is another kind of welding, put the terminal on the lead pole, the position should be placed correctly, with a soldering iron to melt the solder wire, the terminal, pole welding together. When soldering, be careful of false soldering, false soldering.
Introduction of the required equipment: pole group molds, multimeter, oxygen torch, glue gun, soldering iron, bridge welding pliers, air tightness testing machine. Lead battery electrolyte is formulated with pure water and concentrated sulfuric acid, automotive start battery electrolyte density is
1.280±0.005g/cm3((25℃).
② preparation of electrolyte containers, must be acid and temperature resistant glazed ceramic, glass tank, plastic tank or lead lined wooden tank, preparation, the staff must wear protective gear;
preparation of the vessels before scrubbing clean and cleaned with pure water;
preparation of the electrolyte, should be the first to be used in pure water, into a container, and then sulfuric acid slowly into the pure water, and constantly stirring, it is strictly prohibited to use sulfuric acid. Then pour the concentrated sulfuric acid into the pure water slowly and stir it constantly. It is strictly forbidden to pour water into the sulfuric acid to avoid splashing and burning.
The conversion formula is d25 = dt+0.0007(t-25)
D25:25℃electrolyte concentration dt:electrolyte concentration when the temperature is t
0.0007:temperature coefficient t:measured electrolyte concentration
1.electrolyte is mainly composed of distilled water and sulfuric acid, in the configuration of the container must be acid-resistant, and clean. And be clean.
2. Staff should be aware of safety and wear acid-resistant gloves and clothes when working. In the operation of once if there is sulfuric acid splashed on the skin, should be timely with water to wash the skin repeatedly. Configuration of the first distilled water into a clean container, and then slowly introduced into the concentrated sulfuric acid, and to use acid-resistant tools to stir. If the temperature is too high, stop adding acid to prevent the temperature is too high acidity splash out, at a temperature of 25 ℃ in the case of 1.1:28 can be allocated. It is strictly prohibited to pour water into the acid during configuration.
3. According to the added acid capacity of the battery, the capacity of the battery shell, the density of acid, charging and discharging in the grouping loss in order to calculate the amount of acid, because charging and discharging grouping no longer pumping out the acid.
Introduction of equipment required: distilled water apparatus, glass cylinder, pipette, optical detector, hydrometer, etc.. Unscrew the exhaust plug, be sure to penetrate the holes on the plug, there are gaskets and sealing paper under the plug, which need to be removed after acid filling;
Electrolyte temperature must be cooled to below 30 ℃, filling batteries;
Preparation of electrolyte is injected into each single compartment, the liquid level of the plastic-case batteries is flush with the outer shell marking max, and the level of the liquid in the rubber tank batteries should be higher than the partition plate by 10-15 mm;
Tighten the air vent plug to prevent acid leakage.
Introduction of required equipment: coding machine, heat sealing machine, acid filling machine, acid extraction machine, etc..