Understanding Non-Uniform Filling in Positive Tubular Plates
By the author of the Amazon Bestseller Book 'Batteries Demystified', Podcaster, & Expert in Lead Acid Battery Manufacturing Processes and Machines
In this article, we address a specific and practical question raised by a battery manufacturer regarding the non-uniform filling of positive tubular plates. Below, we explore the multiple reasons behind this issue and provide possible solutions based on field experience and technical insights.
1. Variation in Powder Density
The foremost reason is the variation in the density of blended powder. Stamped density (not to be confused with apparent density measured by Scott Volumeter) must be checked. Inconsistencies may stem from improper mixing or powder quality variations. The mixing procedure and sequence of powder addition must be consistent.
2. Clumping Due to Humidity
High humidity can cause powder clumps. These clumps solidify free-flowing powder and block tubular bag filling. It’s advisable to break clumps with a wooden spoon or hammer and use a sieve. Ensure particle size consistency.
3. Vibrator Frequency and Voltage Issues
Vibrator amplitude may vary with AC frequency or voltage. In DC systems, controller issues can cause erratic filling. Consistent power input is vital. A real-world case involved a vibrator malfunctioning under Generator power but working under Utility power. A frequency regulator solved the issue.
4. Additive Issues in Powder
If additives are mixed with the blended powder, ensure they are fine, free-flowing, and not larger than the active material. Improper additives can obstruct powder flow.
5. Spine Grid Burrs and Oil Contamination
Burrs, often seen in gravity-cast spine grids due to fading cork spray, block powder flow. Pressure die-cast grids may retain oil used in mold release, which also hampers filling. These factors must be controlled.
6. Variation in Tubular Bag Diameter
Differences in bag diameter affect void volume and cause weight inconsistencies. Flexible bags are hard to measure accurately with calipers. You can use a graded mandrel for better accuracy. Source bags from suppliers with strict diameter control.
In conclusion, uniform filling in tubular positive plates requires careful attention to powder characteristics, equipment behavior, and component quality. Each step in the process must be tightly controlled to ensure consistency and reliability. I want you to know that feedback and shared experiences from fellow manufacturers are welcome.
Thank you for reading.
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