Inverter Battery Manufacturing Process In india
In today’s time, everyone is using inverter batteries, and it is expected that you also have an inverter and a battery beneath it. Have you ever thought about how inverter batteries are made, how many types there are, and what components are used to make them?
If you don’t know, in this post, we will provide complete information about them. So, if you want to know, read this post all the way to the end.
Types of Lead-acid Battery
When we talk about lead-acid batteries, their size varies, meaning the battery you are using with your inverter at home may be a flat plate inverter battery (small battery), or it could be a tubular battery. These batteries are also used in other devices like cars, e-rickshaws, etc.
They are all lead-acid batteries, but their sizes may vary. However, the manufacturing process and the components used to make these batteries are the same for all types of batteries. So, here we will explain the process for any type of battery, and it will be the same for all.
Components of lead-acid battery
The process of making a lead-acid battery requires 6-7 components that are combined to create the battery. These components include:
1. Container
2. Vent plug
3. Terminals
4. Plates
5. Separator
6. Cell Packaging
7. Acid
Among these, Container, Vent plug, and Terminals are the three components that you can see on the outside of the battery. So, let’s now understand how each of these components is used in making the battery one by one.
1. Container
The plastic cover on the outside of the battery is called the container. It is made of small plastic pellets, and the color of these pellets determines the color of the battery’s container.
You may have seen batteries in various colors like green, blue, or red. The containers are made using these pellets, and the size of the container depends on the specific battery size, which requires different machines.
2. Lead Ingots Manufacturing Process
Lead Ingots Manufacturing Process: Lead is an essential component in lead-acid batteries. Lead is extracted from old batteries and melted down to create lead ingots. These ingots are not in pure form and contain impurities. They are then put into a furnace, where impurities are removed.
Afterward, they are melted again into a die to create a new ingot. These ingots are then tested in a spectro machine to ensure that impurities have been removed before they are used to manufacture grids for lead-acid batteries.
3. Battery Grid Casting Machines & Process
Battery Grid Casting Machines & Process: Two types of machines are used to prepare grids for batteries: gravity casting machines and pressure die casting machines.
Gravity casting machines are used to create tubular grids, while pressure die casting machines are used to create normal grids. Tubular grids are used in batteries with tubular plates, and they are prepared by adding tubular bags made of polyester material to the grids. After filling, the grids become ready plates.
4. Battery Grid Pasting Process
Once the grids are fully prepared, they undergo pasting. The paste applied to these grids is also made of lead material but contains different elements, which result in the formation of negative and positive plates.
Grids with improper pasting are separated and discarded. After pasting, these grids are referred to as plates. You can differentiate between negative and positive plates by their color; negative plates are gray, and positive plates are brown.
Certainly! Here’s the translation of the remaining information about the lead-acid battery manufacturing process:
5. Battery Plates Curing Process
After the grids are completely dried, they undergo a curing process. They are placed in a chamber where steam is introduced, and they are kept inside this chamber for 60 to 72 hours. After this, the plates are taken out and put into a drying oven, where high heat removes any remaining moisture. These plates are then stored at room temperature for one day.
6.Lead-acid Battery Assembly Process
Next, these cells are placed inside a container. Six cells are placed in one container, and they are connected in series. Each cell is 2 volts, so when six cells are connected, the battery becomes 12 volts. After placing the cells inside the battery container, they are welded together using a welding machine.
After connecting the cells, they undergo testing, and caps are placed on top of the battery using a cap-fitting machine. Vacuum testing is performed to check for any leaks. The negative and positive terminals of the battery are then created, where you connect your inverter wires.
After this, a serial number is printed on the battery. This serial number contains all the manufacturing information of the battery. When you need to claim warranty for the battery, you use this serial number.
Finally, sulfuric acid is added to the battery. Acid is added to the battery only once, and if the battery has low acid, water is added.
7.Lead-acid Battery Charging Testing Process
After adding acid, the battery is charged. After charging, the battery undergoes testing, which includes checking the voltage, current, and gravity.
Once all these tests are passed, the battery is cleaned to remove any acid or harmful material on its surface. After all these processes, the battery is packed into a box and sent to the market.
This is how an inverter battery is manufactured. If you want to know about any other type of battery or have any questions or suggestions, you can comment below the post.
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