Presentation on Battery Making Process

1. Presented by:
Arpit(16284)
Sachil (16280)
Anuj Parmar(16275)

2. •Livguard batteries Pvt. Lmt. SAR group company
•Manufactures lead acid storage batteries.
•Supplies and trades inverter batteries, automotive batteries
etc.

3. BERFOR START WITH BATTERY MAKING PROCESS,
LETS US DISCUSS WHAT ARE THE MAIN Construction of Lead Acid
Battery
 POSITIVE PLATE
 NEGATIVE PLATE
 POLYMER SEPARATER
 SULFURIC ACID
 CONTAINER & Battery Terminals

4. 1) OXIDE PROCESS
Lead oxide is obtained by masses of lead from melting furnaces either by Milling or
Barton Pot process methods. In the milling process, the tumbling action generated by
the rotating mill on solid lead generates heat and then the surface of the lead gets
oxidized. The surface layers of the oxide are removed while the lead particles roll in
the drum. In Barton Pot process a fine stream of lead droplets is produced by
blowing air on molten lead. These droplets are reacted with oxygen and produce lead
oxide.

5. Grid production and parts casting involves book casting,
continuous casting, and strip casting. In all of these
processes, lead pigs are melted down and the molten
lead is poured into molds or continuously cast into grids,
strips, or parts.

9. 60% GREY OXIDE(PbO)
40%RED LED
SUFLURIC ACID
WATER

10. • Positive plates need much more time to form than
negatives. The reason for this is the dielectric
behavior of the cured positive paste.
• Oxidation of the bivalent lead compounds in the paste
and formation of the PbO2-positive active mass
passes through a number of chemical reactions, some
of which proceed at a low rate, which retards the
technological process of formation of the positive
plate.

11. Manufacturers consider the pasting material as a
trade secret,and therefore not reveal this to public
However, this paste material in general is made with
oxide of lead, red lead, litharge, water and dilutes
sulphuric acid.

12. Negative plate reaction
Pb(s) + HSO−
4(aq) → PbSO4(s) + H+(aq) + 2e−

13. GREY OXIDE(PbO)
ACRYLIC FIBER
SUFLURIC ACID
CARBON BLACK
BARIUM SULFATE
expander materials

14. The separators are thin sheets of non-conducting material
made up of chemically treated leadwood, porous rubbers, or
mats of glass fibre and are placed between the positive and
negative to insulate them from each other. Separators are
grooved vertically on one side and are smooth on the other
side.

16. The container of the lead acid battery is made of glass,
lead lined wood, ebonite, the hard rubber of bituminous
compound, ceramic materials or moulded plastics and
are seated at the top to avoid the discharge of electrolyte.

17.  Terminal Casting Machine

18. In this process, all the parts are assembled into a battery case and covered
with the plastic moulds plastic molding plant. This step involves the
formation of positive and negative plate stacks, insertion of separators, inter-
cell connector and plate burning. In this step positive and negative plates are
formed like groups which are strapped to a suitable rack, slipped together
and a separator is inserted in-between them. This separator is made up of
non-conductive material such as paper, plastic or a glass fiber.

20. SUFURIC ACID
 ELCTROLYTE
 Dilute Sulfuric Acid (H2SO4) – It is used as an electrolyte. It
contains 31% of sulfuric acid.

21. Filling and Formation
 After the assembling, battery jar is filled with required
amount of electrolyte through a filling or vent tube. Then, it
is ready for initial charging, which may require several hours
of charging depending on the battery size. Low charging rate
is generally employed that may be nearly one day to several
days. This charge formation may either be dry or wet. In a
dry-formation method, batteries are shipped as dry after the
positive and negative elements are fully charged or formed
and dried in tanks or as an individual plates and are
connected to positive and negative terminals of the battery.

23.  HEAT SEAL WITH PRESSURE
TEST
 SHORT CIRCUIT TEST
AIR LEAKAGE TEST

24. Charging and Discharging

25. Electric power is generated ,transmitted and distributed in
form of AC . Electric power is produced at substation .
Substation transform voltage from high to low , or reverse , or
perform other important functions. A substation include
transformers to change voltage levels between high
transmission voltages and lower distribution voltages or at
interconnection of two different transmission voltages.

26. Livguard batteries pvt. Lmt.has its own substation. The company
has 5 transformers of 33MVA rating.It receives a supply of 66kV
from Akkanwali Sub-station. The transformer reduces the voltage
from 66kV to 440V and 220V and is distributed amongst various
departments of the company.

27. Company gets its supply from Akkanwali substation. The
coming 3 phases do not get directly connected to transformer
but first are connected to protection devices , which are as
follows lightning arrester. Then 66kV line enters energy meter
which measures the amount of energy consumed. After this ,3
phase are connected to isolators through insulators.
• Lightning arrester-first 66kV line gets connected to
lightning arrester which protects the conductors of system
from damaging effects of lightning.

28. • Energy meter-it measures the amount of energy consumed
• Isolator –after energy meter 3 phases are connected to
isolator through insulator. If fault occurs in the system then
isolator can be used to isolate the faults to protect the
system . It is operated manually.
• PT(potential transformer)-these are connected in parallel. It
measures the voltage.
• AB switch(Air break switch)-used to isolate faulty line from
healthy line. 3 phases have their own AB switch.
• VCB-if a fault occurs in the system VCB isolate the fault
from the system.3 phases have their own VCB.It is
operated through relay.

29. •CT(current transformer)-it is used to measure current coming
through VCB. It operates relay . It has some definite output
which can be 1A or 5A , generally depends on C.T. If fault
occurs output of current transformer increases and operates
relay , which in turn trips VCB.
•Transformer-the 3 phases are fed to the transformer which
step downs the voltage to desired voltage . Output of
transformer is again fed to lightning arrester through isolator.
Then phases are connected to VCB, current transformer,
isolator, P.T,AB switch,feeder VCB,C.T

30. •PCC is an important part in distribution of power . It receives
stepped down voltage through transformer LT line and then
redistributes to other power distribution centres .
•PCC are controlling power which is going to utilize in industry
,PCC are primary type of control centres.

31. •These are distribution boards where electrical power reaches
from PCC and from here poweris further distributed to the
machines in the plant and to other connected loads.

32. •Battery making process
•Company s’ electrical structure
•Protection devices
•PCC
•Power distribution boards

33. Objective of the study
To determine the customer satisfaction level about
home service and after sales service.
To know consumer behavior for purchase of UPS
battery. To identify the factor which influence on
consumer’s decision.
To identify the loopholes in service process.
To know which service process play important role in
providing after sales service.
To know the possible area of improvement