Document Yjb9oJEog1VqZaQ7YEBJXLzkK

MI . .iiiiii i iw i im ........... i-M'.ii if.--iMBhi LIA15577 LEAD INDUSTRIES ASSOCIATION, INC. IM MADISON AVKNtll NIW VONK IT. N. V, k m noczss ais Asaxau morincM * H THA IZAd-ACIS BAnSST ar m. c. i. rams tics lyiridwt Engineering, (Bobo Satiety Oo. Divisim of dobe-Onicn, Xm. Milwaukee 1, Wio c mIi The lead-acid storage battery, a lOO-yoar-cld product, has lad an eonncario growth coinciding with that of tho anUaoblla. Today, close to 35 8. L. I. batteries are produced ewefViy In this country by on Industry with sa annual dollar values grantor than 300 nUllon dollars. Contrary to tha opinion of aany who only think of a battery whan thatr car doem't start on a odd winter morning, there has basn continuous tecteolo- fed growth In this Industry. Far eoanple, In the early 1920's, load was esets a pound, labor was $0 oacta an hour, and a battery for a Ford or Chevrolet cost the constrasr about $*<0.00. Today, forty years later, lead costs 10 cents a pound, labor $2.$0 an bour, and yet tha ooet to the -- la leas than half that of 1920. Further, tha eleetried load dirm4! of tha aodsm car hsTs Increased affread ately 200f In the last decaae. At the sene tlae, trends In styling bats posed constantly greater pbyalcd Unitattoos on the deelgt of the battery. The pality of today's batteries la decidedly better than those wade forty years ago. For sample, tho average serrioe life of a battery has Increased (as aboie la Figure 1.) In addition, today's battery Is only slightly larger then It was twenty-five yaare ago, yet It Is capable of delivering twice as such eleetried energy. Perfomance data representing gains by the Industry are shown In Figure 2. In spite of greater service danirile and higher naterld and labor eoeta, tha coat to tha eteener has bean reduced. And he's getting a batter product. This la tha result of continued engineering effort to inprava eterid afXiclcy and develop wore efficient aanufacturlng processes and equipment. Tha gain In naterld efficiency over the years la ahmei by the data preewted la Figures 3 and 4. Presented at the 3Ath Annul Meeting, Lead Industries Association, Inc., St. Louis, Mo., April 10-11, 1962. P "S ' .emMsa^i-nlngiiiii*' ml-fini ' i WrAr. atarnMi-M LIA 15 578 JtAA~^k`-"" *'' - --- r.T.x. Lead-Acid Battarlaa - Tear 1962 Figure 3 glvae a ecMparlsee of the amber of 100 aspere-bour antoMotlre batteriae that have been obtained fran 100 pounds of lead cadda. In tba 1920'a, only 6 battarlaa were produced par 100 lba. of lead cadda while today an average cf 11.1 battarlaa ara produead -- an 80JC iaprcvment In Material effi ciency. In Figure 1, eoapsreble data ara abend for tba amount of load grid natal used In battarlaa. In till* ease, a 163 lnprcvaMact In mtarlal effici ency baa baan raallaad orr tha 10-year apan. Tba data In Figures 3 and 4 ara lust one aathod of eapreaelig tba Inprcvmants aada over tba years. Tbaaa algnlflcaat laprovmMta oould alao ba expressed In tame of watt bourn par unit of weight, volrne, and coat which, together with cyda Ufa, ara actually tba baalo crltarla for evaluating all anar& storage darloaa. Thla athod, using tha ebanga In mount of load par battary over tba yaara, was aalactad to lUustrats to you, m*whra of tbo load Indartrlaa, tha trend In our Industry nocaasltatad by custcner dmands and tba usual mpetltive pree auras. It Is only correct to point out that tbaaa irprerrmanta bars baan tbs rasult of not only tbo afforta of tba battary Industry, but alao tbo offarts of tba load and otbar suppllara. Obviously, it Is not poatlbls to ralato what tbo whole Industry la doing to furtbar throve tbo quality of tba laad-seid battarlaa, but In this papsr sms of tba anglnaaring prograoa actively bolng purauad within tba Battery Din sion of Qobe-Onioc, Inc. will ba dsacrlbad. To find out what ara tba caserns of fallnra of battarlaa lu actual fluid service, wa bars a coctlnuoua and aactanaive product partemanes evaluation program underway. We call It tba STAT Survey Syirtm. Working with our custmara, aach year we pick up frm the field many tlwiMndi of Junk battarlaa of both our on and competitors mice. Tbaaa battarlaa ara completely analysed. Cauaaa of fallara ara datarclnad and registered In a 00ctrolled tabulating card *7*toe. Equating cause and fraquaney of fallnra to tba volume of battorlaa produead In a given area and tins, tha wailmataaa of tba battary mtarlala and design can ba determined. This lnformtlon is of great value In directing our engineering progrma. During tba last year and a half, for maple, It reeultsd In tha axtanalon of tba national average service life of Globe 'a battarlaa by two Months. CM of tba major cauaaa of battary failure is tba corrosion or breakage of tba positive grid. Others are Mechanical defects such as ooctalner or post break age, failure of negative plate*, abeddlcg of tbo poaitlve plats, and separator failure. We at Globe have extensive development program underway to correct or retard all these causes of failure, tba alas of tba effort datamlnad by tba mgnltuda of tba fallara. for ample, we are devoting considerable effort to radioing positive grid eorroelcn. Ve believe we have found the mjor causes of grid fallnra, and ara davalopirg Methods of aliml rating these defects. Our preliminary experimental data show that It should be possible to double tba life of tha grid. Baaulta of thla study, together with other mterlal studies which will ba released In apprcxisately a year, will point the way to further reduction In the weight of the lead In a battary and still allow greater margy output per unit of weight and velum. lomipp mm f'~* jViaa-i' L IA15579 ' "-*- -> Tfftlif'il! >' Dp . C. ^. Morehouse > Xeed-Acld Batteries - tsar 196* -- Za thla paper, two d m devslopoents which result la improved prooeaeee and pro* duct* will be reviewed. The first of thaaa la lha cast-oo-etrep prooaea and tha aaoood, the lrrtarosll cormactor design, resulting la a product know aa lobe'a H-V (high voltage) battery. CA3T-0K-amP FB0CK8 Since tha Introduction of tha lead-acid automotive battery tha ecnatmetleo at tha oalla haa bean much tha earns. Each oall consisted of Multiple flat plate aliments with luge on each plate. In one standard Method of aieiMy, tha stack of plataa with aeparatora latarspsrssd la placed la a Jig and a pra cart oasb la placed oo tha plate lugs la tha stack, aa Illustrated la figures 5, 6, and 7. the lugs and comb are fueed together by aaana of a gaa flams torch which la either operated by band aa la figure 5 or fixed aad tha uieMj moved through tha tlmm aa la figures 6 aad 7. Thla Method of assembly haa been eetiafaetaiy, but thero are ahartcaslngs, particularly la tha iaman variables which are nacecaarlly pro* aeat la the lead Maltlag and fusion oparatlco. Thla Method allowa oeoaalcoal lead rundowns between tha plataa, caaalng oall aborts which cannot easily be detected. Secondly, It la difficult to get perfect aligmemt of the lead oall terminal posts, amklng it difficult to assemble tha ocrers co tha battery. In addition, thla ocnrsntlcnal method of aaswdVly doe* not enable the operator to make a cell with a tight stack of separators and plates, - a feature Important for tha battery to withstand severe vibration oomdltlona la aerrioe. Sines 1890, many attspta have bean Made to eliminate this method of aaawdily aad la place of tha ocmb and lead burning process to oast a lead strap and ftoae directly onto tha plates. To our knowledge, tha Globe-Onion cast-on-strap process la tha first aad only practical method developed for this purpose. Vs begin with tha aaaa stack of aeparatora and plataa, but tha lead post la east and fused to tha element In one operation. Tha equl;meat, designed for this process and now la operation in 14 of our 16 plaata, haa four stations aa shown la figure 8 and Illustrated la detail la figure 9. In tha first position, tha stacks are loaded with the lugs la tha downward position and are bald rigidly la clamps. In the second position, tha luge are cleaned and conditioned, and at tha third station tha strap and poet are cast. At tha fourth station, tha alnenta or oalla are unloaded onto a conveyor from Which thsy are assembled Into containers. A typical element sssenMy obtained from thla equipment la shma la figure 10. Tbs advantages of thla process and equlpaent over tha conventional method of burning erst 1. Mo lead rundowns between plataa as the strap and post are oast la tha upside-down position. 2. Improved poet to plate alignment. The poets are parallel to each other and, also, parallel to both edges and the faces of the plates (figure 10). w ^wftpam' p pm. i. ip LIA15 56 o P fir. C. I. lionhsBM i- lnd4eid litUriN - Tear 1963 3. ttgroved qtnter illgmit A. niadratten of atumd Nfutton. 3. Consistent rtaint tightness. 6. agreetd vibration characteristics. A tight stock rtl<i An I*u ylUUn|. Tlhratiou mliUaM Iwprovsasnt* of VX& are achieved. 7. OondiUnt pint* to srtrap Itda. S. Cleon load posts resulting 1b improved link burning and tha ollalnation of the high rotUUnoo link o o c d w Uo m. 9. Seduction la labor usd process variable# associated with Uo operator. 10. Stop to Mtcaotlea. DfTPaai, CCWBCta -- nr fwiw Toltaao) Battery. Ja tbo standard battery asssrhly, tho ports of arch coll or si set protrude through tbo eocrtalBor cover and are connected above thr cover with preoast load link aa about) la figure 11. This construction, while naad for tba loot fifty years, has hod mtmm obvious disadvantages. Tba load links on tha top of tha battery (particularly 12-volt betteriee) mt o subject to corrosion frcai acid creeping op through the rubber or lead buMiy around the posts mud fraa splllaga through tha vast oaps. Thara was also a production prohlsa In covering tha links with a oepound that would resist acids and wids twparaturw changes, yet eould bs r*"*-* to giro an attractive As previously ahoi la this paper, thara has bsen a aarfced lacreoso la d--nd on tha battery. The Industry has ast thsss requlrimts to seas soetsBt by iacreasing tbs nirface area of tbs platss, using aors and thinner plates, wd lower resistance separators. On* aspect which has been overlooked, however, is the internal realstanoe associated with the long poets, links, sad link-post connections. Tbs obvious eolutloo would bs to bring the cell connector direct ly through the partition, thereby reducing the length of tbo path ter the flow of ourrsat. Tbo idea of an intarcell connection is not now. Like the east-co-strap process. Many attenpt* have been wade over the year* to oaks a connection of this typo. The Methods which have been triad Include the use of rubber gjmets, lead bolts with crisping devices, end other rsdioal aeons. To our knowledge, nans are being used in automotive production or hero boon found practical. Vlth the dsTalopnsnt of the east-an-strap process and resulting lapreved align ment of the post, strap, plates, and separators, it beoaae possible to develop a praetloal process for asking a liquid-tight connection directly through the .iwisjijiiJipBfeEW) OPW* ...... ym MTr . a^-ea^ *...------ *-- -- g- [. __ V1. . . ... v-Yjf 'nfif^^----- t*. C. ^. Marabout -5- leed-Aeld Buttsriea - Tear !*! partition of the container. This ho* bow aooenpllahed by punching * bolt 1b the partition, constructing ail* and fowl* button oc tba positive and --f~ tive posts on tba colla and eonpresalca and raalatanoa voiding tba load button# through tba partition to adjaeant oalla. Ouch a construction la she-- In Figure 11. Hr earahil allgcnant and control a rigid, alectralyte-tigbt aaal la -- obtalnad. Twelve tbouaand battarlaa of this construction have baan nada and flald tested with satisfactory raaulta. An Illustration of tba production squlpant which la In oparatlen now la abow In Figure 12. Tbia la a fully ant mat In --chine consisting of throa stations i aligning, veldlxg, and tatting of lntarcall valdad oconectlona. IB addition to tba obvious natarlal and labor Barings aasoelatad with this latereall connector process, tbara la a decided Iwprmr--ant In product perfamaaee. Thla la a raault of tba lower lntarnal raalatanoa of tba battery. In Figure 13 ara abceti dlacharga data obtalnad oc 60 anpara-hour battarlaa with ocoventlcnel el--ants and flat back nechanlral aaparators with resistances ranging between O.OJO and 0.035 ohna/eq. In. Tba data vara gathered at a dlacharga rata of 300 a^erea at 0* F. representing tba cranking ecoditlcns of an eutcnoblle In tbs winter. Tba EPX data equated to battery roltage were obtalnad fr-- ana of tba largo ear neaafscturar's laboratories. It can be ease that, after 10 seocoda at dlacharga, tba H-V battery glrea batter than fOt greater ROTs (or cranking power) than the conventional battery. Furtharoore, tba saw battery glvaa tba aana cranking power at tba and of 30 aannnde of discharge that tba oonvsntlcnal battery gives at 10 aeocnds. These are laportant features to the car Mur id la faced with startlig his car on a cold winter naming. Figure 14 glees 5 eeocrd voltage data obtained on High Voltage and ocnvantlcnal battarlaa discharged at varying rates at 0* F. and -20* F. These battarlaa are the 24.1-60 type. They consist of plates 5-11/16" wide by 4-3/4" high and sepa rators with 0.030 otns/eq. In. resistance. Tba advantages of the naw high voltag*) oocnector batteries In teres of Increased power ot low t--peraturee are atwloue. Additional data laportant for the desip} of future battarlaa are given In Figure 15, ahowlng the Bering* that oould be realised In the --para hour capacity and, in turn, lead cartda If a battery wars designed to deliver a specified voltage at a dlacharga rate of 300 aapsres at 0* F. Couparsble gains at other dlacharga rates and t--paraturea oan also be realised. Hi--Ing up, tba advantages of tba new latercell oomeotor as utilised la tba new B-V battery arei mtocr vnumm 1. Blghar startle voltage. 2. (beater power at high loads* ^proved cover deelgn -- acre apace tor product Identification. Plalnatlen of Hide oorroeicn. PlBlnat1.cn of redn eenpeoad. > .. ilhliiiii iM.ti.mMai im "ilttitiiiMMi 'iriaiir nidMfiU WfMadaa Ik1. C. X. Morabouaa -6- Laod-Aeld Bottarlaa Taor 1962 6. laaa walgfet. 7. Mactlalltlsa of tha Assign of mmUt bottarlaa with mm pomr output at high drolna and low tsaparaturaa. PROCESS IKS KCDWHT 1. taduction of porta and handling. 2. 13Inination of link boning. 3- gllnlnotion of proooaa prohloM oasoclatsd with bubhlaa and Mlatara in the roain ocopound. 6. Lasa proooaa stops and vorlablas oaaoclatad with teaan alanaot. $. A aors ocnalstact quality larrsl boronaa of tba mtr--tin sqolp- Mnt aaod to ooriy cut tba proooaa. Tba eost-oo-strop and tba lstarcaU oonvaetor ora anoplas of what la baing in tha wsridjg of laad In tba battary induatry to prerlda a hlghar quality pro* duct with on laprorsd perforaanco through odroncaa in product daalgn ad Ha* facturing innorattar.a. Pndoobtadly tbara ora othar laportant anglnsarlng daraloptar.ta which will further laprova tba offleiancy of tha laod-oeid powsar aourca. Aa tba product la lnprorod through tba oontlnuad collaborotiss affcrt ( your Inrtiiatry and oura, naw applications for tba laad-ocld battary will bo daralopad which will raault in a cantinaad aconcolc growth for ua oil. (1) Tba Btoroga Bottary Moaufocturlng Induatry 1961 Taor Book, paga 21. Tba Aaaoclotion of Aawu*ican Battary Mnufoetarors, loo. (2) "Tour Battary As Tba Aatonoblla Saaa It," ty D. L. Boyaa. Addroaa dalirarad to tba Oil Induatry TBA droop 1952 Conrantlan. 8t. Louis, Missouri p vnaipywMi