FIELD OF INVENTION
This invention is directed to an apparatus for burning battery posts to the lugs of the assembled plates with separators in position to form a battery cell element. Thus, the present invention relates, more particularly, to an apparatus for burning connectors to terminal posts of assembled storage battery elements.
RELATED ART
Large industrial and motive power lead acid storage batteries are manufactured in small lots in a job shop type environment. Various of the manufacturing steps, including the attachment of terminal post straps onto the lugs of battery cell plate groups, are inherently slow, labor intensive, and not easily subject to change-over for different sized batteries.
A common method of attaching terminal post straps onto plate lugs has involved securing a plate group in a comb-like fixture in a burning box, locating a pre-cast terminal post and strap on the plate group, melting the plate lugs and the terminal post strap by means of a manually held gas torch, adding additional lead by melting a lead stick, and simultaneously stirring and mixing the melted lead to break down surface tension between the lead alloys and to free the mixture of entrained impurities. Not only does such manual torch burning fail to lend itself to be used in automated battery production lines, but the procedure cannot be carried out with consistent quality and can create a hazard to the working environment.
Another method of attaching straps to plate lugs has entailed compressing and positioning the plate group in a basket-like container, inverting the plate group and positioning the lugs thereof in a mold, adding molten lead to cast straps on the lugs, removing the plate group with the cast on straps from the basket, and re-compressing and positioning the plate group into a battery container.
In sealed, valve-regulated lead acid batteries, the plate group includes separators made of relatively fragile glass mat material between the individual plates. Repeated compression and handling of the plate group can damage the separators and adversely affect performance and life of battery. Even in unsealed, flooded lead acid storage batteries which do not utilize such glass mat separators, the plates are fragile and a plastic top separator piece must be used to prevent damage to the separators from insertion of a hydrometer for testing the acid during battery usage.
US patent no 5836371 and 5,972,535 discloses a method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable and inexpensive plastic mold insert.
US patent no 3,597,825 relates to a single station in a lead-acid storage battery manufacturing facility where at the individual cell groups may be assembled, and where the inter-cell connections are made and the battery posts are installed.
US patent no 2,430,188 provides a machine for accurately positioning battery plates and separators in groups and for joining lug straps to the plate lugs in such relationship to the separators that the latter are retained against upward movement in the battery cells by contact with the straps. The machine provides a novel means for automatically applying lead burning jets to assemblies of plates and straps for predetermined period of time and in such a manner as to insure uniform and rigid joining of all lugs to the straps while eliminating danger of dropping lead between the plates.
US patent no 3,138,860 discloses a machine that consists of reversible electric motors connected through a train of gears to a longitudinal rotating shaft suitably journaled on base portion.
US patent no 2,807,227 discloses a means for assembling battery plates and plate separators into elements for such a battery and for interconnecting the lugs of the plates thereof by fusing or burning plate lug straps thereto.
US patent no 2,764,115 discloses an apparatus for use in manufacturing storage batteries and an apparatus for burning connectors to terminal posts of assembled storage battery element and for facilitating insertion of the connected elements into a battery casing.
US patent no 1,389,155 and 1,531,753 discloses a machine which burns the straps to group of battery plates supplied thereto and provides a machine by which the operation can be carried on rapidly, efficiently and continuously or without liability of interruption by some part or parts not working smoothly.
US patent no 1,625,384 discloses a battery plate burner wherein the plates may be expeditiously handled and economically joined.
US patent no 1,948,120 is directed to a machine in which makes the metal flow into a closed mold cavity furnished with a reservoir above the level of the cavity whereby the formation dross and imperfection is eliminated and a properly finished article is produced.
US patent no 4,164,310 and 4,074,423 relates to a system for assembling industrial or motive power batteries. These are provided with automated burning apparatus wherein a plurality of torches are adapted for a square movement across the terminal lugs of the battery stack, thereby facilitating the formation of battery straps and terminal posts on each of a plurality of battery stacks during a single operation.
US patent no 4,050,501, publication no CAl 112486 and CAl 102410 discloses an automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries
US patent no 3,813,024 and publication no GB1407454discloses a multi-stationed battery assembly machine which affords a simultaneous three station operation. At the burning station, the lugs are melted to form straps and connected to posts whereupon the unit is dropped out of position and moved to a third unloading station.
US patent no 4,114,260 and publication no CAl 104642 discloses an industrial battery stack, wherein positive plates which have been longitudinally wrapped with a perforate or semi-perforate material and these are accurately aligned with respect to the negative plates and separators in the stack during the stacking operation.
US patent no 4,241,780 discloses an apparatus for forming battery straps and intercell connections. Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case.
US patent no 4,386,647 discloses a tool for forming electrical interconnections between the terminal ends of storage cell plate lugs. This tool is particularly suited to forming such welds between the terminal ends of plate lugs which project through a cell case wall.
US patent no 5,520,238 discloses an apparatus for assembling battery plates and includes mould which defines a pair of ducts which supply respective sets of mould cavities via weirs.
Publication no 20030072997 discloses an apparatus and a method for connecting cells of a battery
Publication no 20030003811 discloses modular lug block assembly. An electrical power connection block housing comprises a container with multiple housing pieces connected to form at least two electrical connector receiving areas. Each connector receiving area has end apertures through opposite ends of the container at joints between the housing pieces. A cover is connected to the container, wherein a first one of the connector receiving areas comprises two of the end apertures in a first one of the opposite ends and one of the end apertures in a second one of the opposite ends
Thus, the major drawbacks during burning operation of the cells are lead run inside the cell (which creates short inside the cell), unequal compression, misalignment of plates to separator, dependence of burning operation on the operator skills, Excess labor, high maintenance frequency etc. In conventional burning box, unequal compression was observed which affects the battery performance also. The same problem was avoided using the stopper provided in the new design at the sides which fix the cell compression at the sides of each cell. The conventional box requires manual force which depends on the operator. Also sometimes the separator gets damaged.
With all the above discussed restrictions or limitations, it is required to have automatic burning machine which can encounter the above problems. An improved slidable comb design is made which operates with automatic machinery functions and provides equal load distribution at the centre of the cell to have uniform compression. This makes the operation very simple for the operator. The above mentioned patents insist on ease of operation whereas in the present invention there are three pneumatic cylinders which provide uniform compression/ load throughout the cell. Glass mat separators are used in the invention which reduces the chance of separator's damage and makes it suitable for operation.
OBJECTS OF THE INVENTION-
The primary object of the present invention is to provide a device and method of burning posts to the lugs of the plates forming a cell element which is suitable for use on a mass production line and is capable of being carried out in connection with all sizes of plates which are to be used in batteries having different capacities.
Another object of the present invention is to provide a machine which is adjustable to fit all required sizes of battery plates to cooperate with a universal fixture to hold the posts in position with reference to the lugs and provide a removable and adjustable mold element so that machine can perform burning operations to affix battery posts to the lugs of the plates forming a cell element for all sizes and capacities of batteries required to be made in the mass production line.
Another object of the present invention is to provide an apparatus and method of the foregoing type which minimizes damage to fragile mat separators used in the battery cell plate groups of sealed and valve-regulated lead acid batteries.
Yet another object of the present invention is to provide an apparatus and method which eliminates the requirement for repeated compressing of the battery plate groups during manufacture.
Still another object is to provide an apparatus and method of the above kind which can be carried out without harm to the working environment.Another object is to provide an apparatus and method which can be used for casting straps onto lugs of battery plate groups for use either in sealed, valve-regulated lead acid storage batteries or unsealed and flooded lead acid storage batteries. When used in the
manufacture of the latter, it eliminates the necessity for a separate top separator panel for protecting the plates from damage from hydrometer insertion into the battery during usage.
Yet another object of the present invention is to provide a device and method having an equal load distribution at the centre of the cell to have uniform compression.
Still another object of the present invention is to make the burning operation very simple for the operator.
Another object of the present invention is to make compression automatic and uniform during burning.
Still another object of the present invention is to provide a device and a method which can improve the quality of the battery.
Another object of the present invention is to provide a device with minimal maintenance frequency
Yet another object of the present invention is to provide a device which can reduce replacement tooling cost.
Still another object of the present invention is to provide a device which can reduce the process time.
Another object of the present invention is to provide a device and method which lowers rejection levels.
Yet another object of the present invention is to provide a device with easy operational functions.
Still another object of the present invention is to provide a device which is user friendly
SUMMARY OF THE INVENTION
In order to overcome the mentioned problems and to achieve the said objects, the present invention provides an automatic burning apparatus for burning posts to the lugs of the plates forming a cell element which is suitable for use on a mass production line and is capable of being carried out in connection with all sizes of plates which are to be used in batteries having different capacities. A box with slidable comb is provided, which can be operated by pneumatic pressure. Atleast three cylinders with inlet and outlet ports are provided in the invention out of which one is attached with the box and the rest of the two are attached with both the combs. A rod is attached with the cylinder and the air pushes the rod in and out to compress the cell. The box is divided into atleast three adjustable parts which provides a magazine feed stop mechanism. Thus, equal compression in each cell is provided which improves the operational characteristics of the battery.
In an embodiment of the present invention, any number of pneumatic cylinders can be used.
In another embodiment of the present invention, the box can be divided into any number of adjustable parts which provides a magazine feed stop mechanism.
The foregoing as well as additional objects, features and advantages of the invention will be more readily apparent from the drawings and their detailed descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of this invention will be more apparent from the ensuing description when read in conjunction with the accompanying drawings and wherein: Fig. 1 shows a basic diagram of an automatic burning apparatus Fig. 2 shows magazine feed stop mechanism;
DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
Reference may be made to fig. 1 indicating an automatic burning apparatus 100 for burning posts to the lugs of the plates forming a cell element which is suitable for use on a mass production line and is capable of being carried out in connection with all sizes of plates which are to be used in batteries having different capacities. A box 101 with slidable comb 102 is operated by pneumatic pressure 103. Atleast three cylinders 103 with inlet 104 and outlet ports 105 are provided out of which one is attached with the box 101 and the other are attached with both the combs 102. A rod is attached with the cylinder 103. The air pushes the rod in and out to compress the cell. The box is divided into atleast three adjustable parts 106 which provides a magazine feed stop mechanism 107. Thus, equal compression in each cell is provided which improves the operational characteristics of the battery. A magazine feed stop mechanism 107 is provided at the sides of the burning box to have equal compression in each cell. The pneumatic cylinders 103 provided in the battery burning box 100 assembly makes equal load distribution at the centre of the cell to have uniform compression. This makes the operation very simple for the operator.
The guidance 108 provided in comb 102 has a slot which does not provide any free movement to the comb 102. This makes it easy for the operator during the burning operation. The comb 102 can move only in Y direction. The mono-directional movement (Y-axis) during burning operation avoids the other operational problem that occurs during the design of conventional comb 102. Two longitudinal tracks 109 are provided on
the top of the base running substantially along the length of the machine, which supports and guides the two magazine-holding master fixtures, that provides the necessary mold facilities for burning battery posts to the battery plates element.
The illustrated apparatus comprises a box 101, formed by a pair of horizontally spaced slidable comb 102 which can move over the slot 108. Vertically extending, side members 107 are rigidly secured together adjacent to their tops by horizontally extending end members bolted or otherwise secured to the side members. The bottoms of the side members are rigidly secured to a base by brackets and suitable securing means such as bolts or machine screws. Each side member is provided with an opening extending upwardly from the base and of suitable size to slidably receive an open topped battery casing in an upright position with the length of the casing extending transversely of the frame means. Adjustably secured to the base 107, intermediate the sides of the frame 106 are stop members for accurately positioning an assembled and connected set of battery elements as described herein after. In the illustrated embodiment both side members have been illustrated as provided with openings such as, but it will be readily apparent that by omitting one of such openings, the corresponding side members could be made to serve as a stop means, thus eliminating the necessity for a stop. Preferably, however, the stop means are provided as shown to facilitate replacement and/ or to permit adjustment for accommodating battery casing of different sizes.
After the parts of the apparatus have been positioned, assembled battery elements having their plates provided with connecting straps and upwardly extending terminal posts are located in the holder. The two portions of the cover means 102 are then moved to closed position engaged about the end terminal posts and the pairs of openings positioned about the intermediate terminal posts extending above the cover 102 means when thus positioned. Connector members for the battery are then placed over the terminal posts extending through the openings such as with the connectors resting in the recesses. The
cover 102 member is then moved to closed position and a suitable lead burning means such as a flame or the like is applied to the openings of the upper cover member, thus producing sufficient softening or melting of the terminal posts and adjacent portions of the connectors to unite them, as is well known in the art. This operation may be performed by unskilled labor, since the apparatus completely protects the battery elements. Even the intermediate portions of the connectors from improper contact by the flame and the molten metal that might be produced thereby cannot contact the plates or separators of the battery elements. Moreover, even if excessive melting of the posts and adjacent portions of the connectors should be caused, the recesses and the cover serve as mold to retain this metal in proper relationship about the terminal posts and the remaining portions of the connector members.
The pneumatic cylinder 103 provided in the battery burning box 100 assembly makes equal load distribution at the centre of the cell to have uniform compression. This makes the operation very simple for the operator. When the switch 109 is actuated, a system of air valve is activated, controlling the operation of pneumatic cylinder 103. The action of cylinder 103 is transmitted to a longitudinal shaft through piston rod 110 to a universal pivot at the end of the crank arm, shaft being pivotally mounted in bearing blocks and mounted near the bottom of the machine base 101. The same arrangement is also connected to both the sides of the comb 102 to provide controlled motion of the comb 102. It will be seen that the apparatus is readily adapted to automation. For example, simple pneumatic means can be installed on the machine to raise and lower the guides and to close them against the plate lugs by moving forward the plates forward. Automatic burning apparatus 100 can be adapted to the apparatus of this invention, just as an automatic placing apparatus, both for the cell groups and for the inter cell connectors and battery posts.
After the flame or other heating means is removed from the terminal posts of the battery, the cover swings to an open position and the two portions of the cover are separated. The operator then pulls on the handle, moving the holder from its initial position to a position above a battery casing which has slid into position before, during or immediately after the burning operation. The connected assembled battery elements may then be disposed in the battery casing by simply exerting a downwardly directed force on the elements, thus overcoming the slight frictional force imposed by the partition and end walls. The glass mat separators are used in the invention which reduces the chance of separator's damage and makes it suitable for operation.
Water channels can be formed within the combs and particularly within the plates to provide faster heat dissipation and thereby faster solidification of the molten lead alloy forming the bus bars during the burning operation. Due to the above functions, the compression obtained is automatic & uniform in nature.
Figure 2 shows magazine feed stop mechanism. A magazine feed stop mechanism is provided at the sides of the burning box to have equal compression in each cell and hence improves the operational characteristics of the battery. The position of these stoppers can be adjusted as per the requirement by imposing air pressure through the pneumatic cylinder. Thus, load distribution at the centre of the cell has uniform compression. The stopper mechanism provided shall be changed according to the varying cell size.
It is to be noted that the present invention is susceptible to modifications, adaptations and changes by those skilled in the art. Such variant embodiments employing the concepts and features of this invention are intended to be within the scope of the present invention, which is further set forth under the following claims: -

WE CLAIM;
1. An automatic burning apparatus for burning posts to the lugs of the plates forming a cell element comprising of a box with slidable comb operated by pneumatic pressure, atleast three pneumatic cylinders with inlet and outlet ports, out of which one is attached with the box and the rest of the two are attached with both the combs, wherein the box is divided into atleast three adjustable parts which provides a magazine feed stop mechanism and a rod is attached with the cylinder providing equal compression in each cell.
2. An automatic burning apparatus as claimed in claim 1, wherein said pair of horizontally spaced comb is connected with the pneumatic cylinder which provides horizontal to and fro movement to the comb.
3. An automatic burning apparatus as claimed in claim 1 or 2 wherein said comb is provided with guidance having a slot, which does not provide any free movement to the comb.
4. An automatic burning apparatus as claimed in any of the preceding claims wherein said pair of horizontally spaced slidable comb move over the slot.
5. An automatic burning apparatus as claimed in any of the preceding claims wherein a magazine feed stop mechanism is provided at the sides of the burning box to have equal compression in each cell.
6. An automatic burning apparatus as claimed in any of the preceding claims, wherein the box is divided into the adjustable parts providing a magazine feed stop mechanism.
7. A magazine feed stop mechanism as claimed in any of the proceeding claims, wherein the position of the stoppers can be adjusted as per the requirement by imposing air pressure through the pneumatic cylinder.
8. An automatic burning apparatus as claimed in any of the preceding claims wherein the burning apparatus is suitable for use on a mass production line and is capable of being carried out in connection with all sizes of plates which are to be used in batteries having different capacities.
9. An automatic burning apparatus as claimed in any of the preceding claims comprising of switch, actuation of which causes activation of a system of air valve, controlling the operation of said pneumatic cylinder.
10. An automatic burning apparatus substantially as herein described with reference to the accompanying drawings.