NiMH battery packs

Exploring the typical NiMH battery packs process

Lead-acid batteries are mainly composed of battery tanks, battery covers, positive and negative plates, dilute sulfuric acid electrolyte, separators and accessories.

The process manufacturing is briefly described as follows: Lead powder manufacturing: 1# electrolytic lead is made into lead powder that meets the requirements through oxidation screening using a special equipment lead powder machine. Grid casting: Lead-antimony alloy, lead-calcium alloy or other alloy lead is usually cast into different types that meet the requirements by gravity casting. Various lead-acid batteries are mainly composed of battery tanks, battery covers, positive and negative plates, dilute sulfuric acid electrolyte, separators and accessories.

The process manufacturing is briefly described as follows: Lead powder manufacturing: 1# electrolytic lead is made into lead powder that meets the requirements through oxidation screening using a special equipment lead powder machine. Grid casting: Lead-antimony alloy, lead-calcium alloy or other alloy lead is usually cast into different types of various plate grids that meet the requirements by gravity casting. Plate manufacturing: Mix lead powder, dilute sulfuric acid and additives, apply them to the surface of the grid, and then dry and solidify them to form green plates. Plate formation: The positive and negative plates react with dilute sulfuric acid under the action of direct current to produce lead oxide through redox reaction, and then after cleaning and drying, they can be used for positive and negative plates for battery assembly. Assembling batteries: Assemble different types of plates with different numbers of plates into various types of batteries according to different needs. Note: Different units can choose different processes due to different process conditions. Introduction to grid casting The grid is the carrier of active substances and also the conductive current collector. Ordinary open battery grids are generally cast with lead-antimony alloys, maintenance-free battery grids are generally cast with low-antimony alloys or lead-calcium alloys, and sealed valve-controlled NiMH battery packs grids are generally cast with lead-calcium alloys. Step 1: Determine the alloy lead model according to the battery type and put it into the lead furnace for heating and melting. After meeting the process requirements, cast the lead liquid into the metal mold, and after cooling, remove the mold and trim it for stacking.

Step 2: The trimmed grid can be transferred to the next process after a certain period of aging. Main control parameters of grid: grid quality; grid thickness; grid integrity; grid geometric dimensions, etc.; Introduction to lead powder manufacturing Lead powder manufacturing has Shimadzu method and Barton method, and the result is to process 1# electrolytic lead into lead powder that meets the requirements of battery production process. The main components of lead powder are lead oxide and metallic lead. The quality of lead powder is closely related to the quality of the manufacturing. In my country, the Shimadzu method is mostly used to produce lead powder, while in Europe and the United States, the Barton method is mostly used to produce lead powder.

The process of producing lead powder is briefly described as follows:

Step 1: Process the qualified electrolytic lead into lead balls or lead segments of a certain size through casting or other methods;

Step 2: Put the lead balls or lead segments into the lead powder machine, and the lead balls or lead segments are oxidized to generate lead oxide;

Step 3: Put the lead powder into a designated container or powder storage bin, and after 2-3 days of aging, it can be used after passing the test. Main control parameters of lead powder: oxidation degree; apparent density; water absorption; particle size, etc.; Introduction to plate manufacturing The plate is the core part of the battery, and its quality directly affects various performance indicators of the battery.

The production process of paste-coated plates is briefly described as follows:

Step 1: Use special equipment to mix qualified lead powder, dilute sulfuric acid and additives to make lead paste;

Step 2: Use a coating machine or manually to apply the lead paste to the grid;

Step 3: Curing and drying the filled plates to obtain green plates. The main control parameters of green plates are: lead paste formula; apparent density; acid content; paste amount; thickness; free lead content; moisture content, etc. Assembly process introduction Battery assembly is quite different for automotive batteries and sealed valve-regulated lead-acid batteries. Sealed valve-regulated lead-acid batteries require tight assembly and generally use AGM separators, while automotive batteries generally use PE, PVC or rubber separators. The assembly process is briefly described as follows:

Step 1: Load qualified plates into welding tools according to process requirements;

Step 2: Put the cast-welded or manually welded pole groups into a clean battery slot;

Step 3: The automotive battery needs to be through-wall welded and heat-sealed, while the sealed valve-regulated NiMH battery packs needs to be bonded with a special adhesive if it uses an ABS battery slot. The main control parameters of battery assembly: busbar welding quality and materials; sealing performance, positive and negative polarity, etc. Introduction to the formation process Plate formation and battery formation are two different methods for battery manufacturing, which can be selected according to specific circumstances. Plate formation is generally relatively easy to control, but the cost is high and environmental pollution requires special treatment. Battery formation quality control is more difficult, and generally requires high quality of the green plates produced, but the cost is relatively low.

The formation of sealed valve-controlled lead-acid batteries is briefly described as follows:

Step 1: Install the green plates that have passed the test into the battery slot and seal them according to the process requirements;

Step 2: Pour a certain concentration of dilute sulfuric acid into the battery according to the specified amount;

Step 3: After placement, pass direct current according to the size of the specification. Generally, after formation, discharge inspection is required and the group is put into storage for shipment. The main control parameters of battery formation: tank acid volume; tank acid density; tank acid temperature; charging amount and time, etc.

Use and maintenance Lead-acid batteries play an irreplaceable role in secondary chemical power sources with their simple manufacturing process, abundant raw material sources and moderate prices. In particular, the emergence of valve-controlled batteries has brought new vitality to traditional batteries. The service life of batteries is closely related to manufacturing, and also has a great impact on the use method. Correct use methods are of great benefit to extending the life of batteries. For traditional open-type batteries, the following aspects must be paid attention to on a daily basis:

① Pay attention to the amount, density and charging degree of the electrolyte, especially the charging system closely related to it. If the charge amount is large, the battery will lose a lot of water, which is easy to cause the active material of the plate to fall off, causing a short circuit at the bottom to make the internal temperature of the battery high and shorten the life. If the charge amount is small, it is easy to cause the battery to lose power. In the case of long-term battery loss, the battery can cause irreversible sulfation of the plate, which is manifested by a rapid rise in voltage during the charging process, which is completed in a very short time, and a rapid drop in voltage during discharge.

② The purity of the electrolyte is generally filled with battery-specific electrolyte or replenisher. It is strictly forbidden to replace it with ordinary sulfuric acid and tap water.

③ Keep the surface clean and the exhaust port unobstructed during daily use. ④ When not in use, fully charge the battery first, and recharge it once every three months.

For sealed valve-regulated lead-acid batteries, the following aspects should be paid attention to daily:

① Pay attention to the range of charging voltage. When floating charge is used, the voltage is generally controlled at 2.15±0.1V/cell. When circulating, the voltage is generally controlled at 2.35±0.1V/cell. If the instructions require it, it should be operated according to the instructions.

② Pay attention to the ambient temperature, which should generally not exceed 30 degrees. When the temperature changes greatly, the voltage regulation should be strengthened.

③ Products from different manufacturers cannot be mixed, and new and old products from the same manufacturer cannot be mixed. ④ It is best not to open the lid of the sealed valve-regulated NiMH battery packs to add electrolyte and replace the safety valve by yourself.

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