Production Process of Assembly Shop
STACKING
This activity consists of stacking positive and negative plates in a group. The stacking procedure involves placing alternate Negative and positive plates with separators placed in between of the two. The separators are placed so that their Glass Mat side is always towards the positive plate. This is to minimize the shedding of positive active mass during operation. Depending on the type of battery the type and number of plates in a cell is determined during this activity.
ALIGNING
The stacked groups are aligned in a box to facilitate the group welding procedure. The box allows aligning six groups at a time i.e. one battery at a time. Now this aligned box is ready for group burning.
GROUP BURNING
Those groups which are aligned in a box are burned in such a way that negative plates’ lugs are burned with a strap or a pole which becomes a negative terminal/strap and vice versa for the positive plates
GROUP ALIGNMENT
Group alignment deals with aligning the separators in a group accurately so that no short circuit should be observed within the group when those groups are inserted in the container. A worker checks the groups visually so that if there is any problem with the group could be removed before the insertion.
GRUP INSERTION
Now those welded and aligned groups are inserted in the container in such a way that there should not be any mistake in the polarity of the group. Spacers are also inserted as they are subjected to the number of plates.
INSPECTION AND TERMINAL ALINGNMENT
Now manual inspection is done where the workers check either the terminals are aligned or not. Workers can also do the short circuit testing of the groups manually as the checking is provided along side.
SHORT TEST
Now the battery enters in short testing station where a short testing machine checks that battery is polarity wise correct or not. If the battery is short circuited then it is obsolete from the line.
INTER CELL WELDING
After short circuit and polarity test now the groups of the battery are welded together. The welding is basically spot welding. After welding the battery is again tested for short circuit.
SHEAR TESTING
The shear testing of the welded cells is done to check either the weld is strong enough or not. The activity is performed by a worker through a shear testing device which runs on pneumatic pressure.
HEAT SEALING
After shear testing, the battery comes to the heat sealing machine where the container and lid is joined/sealed together by heating them up to certain temperature.
LEAK TESTING
After heat sealing the leak testing of the battery is done. A leak testing machine checks the batteries for leakage between the cells by applying and maintaining air pressure. The machine also checks the container outer walls for leakage. The machine also stamps the lids with coding for the batteries.
ALUMINUM FOILING
Aluminium foiling is done on the vent plug holes where the foiling is included in the design of the battery.
PACKING
The battery which is finished in all aspects is cleaned and packed in a carton with taping on it. Now these packed batteries are placed on pallet.
This activity consists of stacking positive and negative plates in a group. The stacking procedure involves placing alternate Negative and positive plates with separators placed in between of the two. The separators are placed so that their Glass Mat side is always towards the positive plate. This is to minimize the shedding of positive active mass during operation. Depending on the type of battery the type and number of plates in a cell is determined during this activity.
ALIGNING
The stacked groups are aligned in a box to facilitate the group welding procedure. The box allows aligning six groups at a time i.e. one battery at a time. Now this aligned box is ready for group burning.
GROUP BURNING
Those groups which are aligned in a box are burned in such a way that negative plates’ lugs are burned with a strap or a pole which becomes a negative terminal/strap and vice versa for the positive plates
GROUP ALIGNMENT
Group alignment deals with aligning the separators in a group accurately so that no short circuit should be observed within the group when those groups are inserted in the container. A worker checks the groups visually so that if there is any problem with the group could be removed before the insertion.
GRUP INSERTION
Now those welded and aligned groups are inserted in the container in such a way that there should not be any mistake in the polarity of the group. Spacers are also inserted as they are subjected to the number of plates.
INSPECTION AND TERMINAL ALINGNMENT
Now manual inspection is done where the workers check either the terminals are aligned or not. Workers can also do the short circuit testing of the groups manually as the checking is provided along side.
SHORT TEST
Now the battery enters in short testing station where a short testing machine checks that battery is polarity wise correct or not. If the battery is short circuited then it is obsolete from the line.
INTER CELL WELDING
After short circuit and polarity test now the groups of the battery are welded together. The welding is basically spot welding. After welding the battery is again tested for short circuit.
SHEAR TESTING
The shear testing of the welded cells is done to check either the weld is strong enough or not. The activity is performed by a worker through a shear testing device which runs on pneumatic pressure.
HEAT SEALING
After shear testing, the battery comes to the heat sealing machine where the container and lid is joined/sealed together by heating them up to certain temperature.
LEAK TESTING
After heat sealing the leak testing of the battery is done. A leak testing machine checks the batteries for leakage between the cells by applying and maintaining air pressure. The machine also checks the container outer walls for leakage. The machine also stamps the lids with coding for the batteries.
ALUMINUM FOILING
Aluminium foiling is done on the vent plug holes where the foiling is included in the design of the battery.
PACKING
The battery which is finished in all aspects is cleaned and packed in a carton with taping on it. Now these packed batteries are placed on pallet.