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Lead Melting furnace of 400 kgs capacity to inside electrically heated with 6 Nos tubular heaters enclosed in three fabricated frames to prevent damage to heaters at the time of feeding lead ingots complete with electrical control panel suitable for mounting on wall. The electrical control panel shall have a temperature controller connected to a thermo couple fitted to the furnace and shall also have a timer to enable automatic switching ON at preset time prior to start of shift. The furnace shall have a hood for fume escape through a chimney. Ducting to chimney and chimney shall not be in our scope of supply.
Serial nos. change automatically after every punching.Height of punching mechanism made adjustable to suit battery height.Punch mechanism electrically heated and simple controller provided.Can be placed in line with the assembly equipments.Effortless punching mechanism ensures clearly visible numbers.Traceability of product ensured for future reference.7 digit numeric punch usually supplied as a part of the machine.Fixed alphanumeric punch can be supplied on specific request-optional extra.Changeable letters and numbers can be given as a set-optional extra.
The UNIK Air Pressure Leak Tester is an equipment which will ensure that batteries with even minor leaks are detected. The equipment is a programmable micro processor based unit with various time settings that can be programmed through the keypads on the front of the controller. These timings are:
1. Fill Time during which the test pressure is filled in the component.
2. Settling Time during which the test pressure is stabilized evenly over the entire volume of the component.
3. Test Time during which the test component is subjected to leak test.
4. Exhaust Time used to exhaust the air from the test component.
The settings of test pressure and permissible leak can be easily programmed with the help of keypads.
The detailed test status and test results are displayed on 16 x 2 character alpha numeric LCD display providing record of the measured leak for each test along with other programmed parameters.
The operating procedure is very simple once the battery under test has been clamped and test started. Once the equipment is started, the pressure fill cycle starts. The set test pressure is filled in the battery. This cycle continues till the set air pressure is filled within the set fill time. After fill time is over the inlet of air into battery is stopped. At this point of time if the pressure is not filled upto the set pressure specified limits the controller gives a Gross leak signal. In case there is no gross leak; settling time starts with the pressure stabilizing evenly in the battery compartment under test. After the settling time is over the test time starts.
At the end of the set test time the reading is checked automatically and a comparison of pressure with preset value is done. If there is a drop in pressure during the test time and if this drop is greater than maximum permitted leak the fault indicator glows. In case the leakage is within acceptable specified limits the OK signal glows.
An audio visual alarm helps in segregation of acceptable and rejected batteries thereby eliminating any possible error due to the operators subjective judgment.
A side view of the machine with brushing arrangement clearly visible.The dust collection is effective & behind the brush mechanism with blower fan on top. Salient Features:
Utility Requirements:
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| FAQ's | |
| 1. How important is lug brushing? Is it really necessary? Lung brushing is important and hence necessary prior to group welding in the assembly department since removal of oxide from the lugs exposes the metal surface thereby ensuring a proper welding and bonding of the plates to the busbar. 2. In what way is lug brushing on machine butter compared to filing the plates? Manual filing of plates can result in uneven lug thickness causing lead runs during grouping. Such lead runs if undetected can be the reason for cell shorts and battery failure. Thus it is a quality related issue. Moreover filing of plates manually is laborious, time consuming and hence not economically viable. Further in addition to productivity the rate of production with manual filing is low and hence unviable considering the competitive nature of todays business environment. Lastly and not the least manual filing is polluting whereas the lug brushing machine having theintegrated dust collector ensures that the lead dust is collected in a tray resulting in substantialsavings for todays battery manufacturers clean setup. 3. Can the machine be used for industrial plates lug brushing?The machine can be used for positive & negative plates of standard size as well as narrow size automotive plates in addition to using these for all industrial plates. 4. How frequently does the filter media need cleaning? Cleaning of the filter media is done periodically with the help of compressed air. It is for this purpose thatcompressed air forms part of this machines utility requirement. A timer in the control panel ensures cleaningof the filter at regular intervals of one minute. |
| 1. Capable of dry charging automotive and industrial battery negative plates.2. Batch process gives consistent quality plates with over ninety per cent free lead content.Plates have high capacity charge retention.3. No environmental problems.4. Compact size with low layout cost.5. Automatic cycle duration of eight to ten hours.6. Rugged construction.7. Easy to operate.8. High productivity.9. Low maintenance costs.10. All work instructions documented and given.11. Maintenance and service manual supplied along with the machine.12. Operator training provided at our works.13. Standard components used in the manufacture.14. All safety parameters considered.15. No fumes or residual waste.16. PLC and data logger ensure accurate process control. | |
| FAQ's | |
| 1. What are the advantages of selling a dry charged battery as against a dry uncharged battery assembled with formed plates? A battery dealer is a person who never wants to displease his customer and at the same time wants to have the maximum business. This is not unusual in any region and understandable from the businessmans point of view. If a battery manufacturer gives the dealer a dry charged battery the manufacturer and dealer derive the following benefits:- 2. Is it possible to use the dry charging machine for drying industrial battery (stationary & traction) negative formed plates ?
Yes the machine can be used to dry the formed negative plates of any type of lead acid battery. I.e. automotive, motor cycle, SMF, stationary, semi traction or traction battery. 3. In what way is a dry charged battery different from a battery made with formed plates ? In the case of battery made with formed dried plates the positive plates are fully charged whereas the negative plates have discharged after formation due to the oxidation reaction which is an exothermic reaction that has taken place when the plates were taken out of the formation jars. Due to this phenomenon batteries made with formed plates need a long duration of charging at a slow rate of charging i.e. low current input. The input in terms of Ah is also high. Basically the negative plates need to be charged without heating up the positives which are already fully charged. In the case of battery made with dry charged formed negative plates and dried formed positive plates the batteries can be commissioned fast since the negatives are not discharged after formation. 4. For how long a duration do the negative plates stored as plates retain its dry charge characteristics? The retention of dry charge characteristics in negative plates shall depend on the method of storage of plates and the nature and quantity of certain additives in the negative paste mix. If the plates are not exposed to atmospheric moisture and oxygen the period of storage can be as long as 12 to 15 months. It is therefore necessary to cover the fully dried cool plates with polythene wrapping in a suitable manner. Dried silica gel pouches in cotton bags help in keeping plates dry. Further at the time of negative paste mix preparation an addition of oil or stearic acid is recommended. This forms a protective layer on plate surface preventing oxidation of negative plates with a consequent loss of dry charge characteristics. 5. For how long a duration does an assembled battery having dry charged negative plates retain its dry charge characteristics? The retention of dry charge characteristics in an assembled battery shall depend to a great extent on
Since moisture from positive plates can travel to negative plates and start the oxidation process it is necessary to dry the positive plates also thoroughly before assembly.Residual acid in either positive or negative plates can cause deterioration of dry charge characteristics since the hygroscopic sulphuric acid can attract the atmospheric moisture leading to oxidation of negative plates 6. What is the quality parameter which indicates that the dried plates are of acceptable nature? The free lead content in the active material of formed dry negative plates taken out of the machine after correct processing is an indicator of the quality of the plate. 7. How can this free lead content be verified? This can be verified by chemical testing in the laboratory. In case detailed procedure of testing is required please contact M/s Unik Techno Systems Pvt. Ltd. 8. Is there any other simple method which indicates that the dried negative plates are of acceptable quality? A simple indication is available if it is observed that the assembled battery
over a one hour period after filling of acid in the battery. 9. How important is the washing of negative plates prior to dry charge process? It is important to wash the negative plates free of acid and check whether the wash water pH is between 5.5 to 6.0 prior to loading the plates on to the dry charging chamber. Please note that it is equally important to load the washed plates into the machine within an hour of such a complete wash free of acid. In case the plates have to be stored for a long period in water after washing, it is necessary to retain some acidity in the water. Hence it is recommended to do the washing in two stages. In stage one wash plates such that the wash water pH is around 4.5 to 5.5. Keep negative plates in a tank of such an acidic water. As and when the negative plates are to be dried and approx. an hour or so prior to loading into the machine the second stage of washing can be carried out i.e. plates can be washed to a pH of 5.5 to 6.0. If the plates are not washed completely free of acid prior to loading on to the machines the seals of the vacuum pump shall get damaged leading to machine breakdown and production downtime. |
| 2. Ideal for small batches of even 800 to 1000 kgs. oxide pasting | |
| 3. Variable frequency drive to vary belt speed provided in control panel | |
| 4. Low on maintenance cost | |
| 5. Unskilled workmen can be easily trained to operate the machine. | |
| Technical Support | |
| 1. Trial run can be done by pasting your grids at our works prior to dispatch of the machine. | |
| 2. Trial run can be done by pasting your grids at our works prior to dispatch of the machine. | |
| 3. Necessary guidance on aspects of machine installation shall be imparted and demonstrated at our works free of cost. | |
| 4. Detailed manual shall be sent along with the machine at the time of supply. | |
| FAQ's | |
| 1. What is the expected life of the Pasting Machine Belt?The Pasting Machine belt if properly cleaned and maintained as per recommendations can be used for 3, 00, 000 nos. of grids or 5, 00, 000 nos. of grids depending on your choice of belt i.e. it shall depend on whether you are using the Make A or the Make E belt supplied by us. | |
| 2. What is the approx. cost of belt in relation to the plate cost w.r.t pasting operation? Considering the cost of belt and the output from the belt in terms of belt life the cost works out to 4 paise per pasted plate. | |
| 3. In terms of maintenance what is the care to be taken and what are the spares to be maintained.?It is imperative that the machine is to be kept clean by washing thoroughly after the pasting has been completed i.e. at the end of the shift. As regards spares for maintenance purposes except for a few springs and paste scraper to scrape the paste from the belt and from pasted plate edges there are no spares to be maintained in stock by the user. | |
| 4. Is it necessary to maintain any other consumables as spares and if so what is the quantity recommended to be maintained?We strongly recommend that you maintain at least two pasting belts as spares at your end and also one roll of roller cloth at all times. This shall ensure that you can have an uninterrupted operation at your end without having to resort to last minute courier dispatch from our end. |
| Machine Size | Control Panel Size |
| 1500 mm L | 200 mm L |
| 1100 mm W | 300 mm W |
| 300 mm H | 400 mm H |
| A Full View of The Filling Machine Complete With | |
| - Feeder hopper | |
| - Blender | |
| - Rotary valve | |
| - Vibrator with hood | |
| - Bottom bar fixing station & dust collector | |
| FAQ's | |
| We understand that there are certain queries that often asked and so we decided to bring forth to You, our clients and customers a common platform where all frequently asked questions and queries are answered to the best of our abilities. 1. What is the vibration mechanism ? The vibration is achieved by using a electromagnetic vibrator table. It has been observed that dry filling of fine lead dust in tubular bags is best achieved using such a mechanism instead of unbalanced motors or cam type vibrators or jolters. 2. Can the vibration be adjusted ? Yes it can be adjusted using the controller provided in the control panel along with the Positive Tubular Plate Filling Machine. Additional settings can be done by adjusting the vibrator base bolts. Please refer to O & M manual for a detailed sketch and instructions pertaining to this adjustment. 3. Can the Positive Tubular Plate Filling Machine be used to fill 6 mm dia tubular bags ?Yes the machine can fill plates having.
The actual time of vibration filling is 1 mins. However the loading of grids fitted with tubular bags into the cassette, subsequent vibration and unloading of filled plates from the cassette usually needs 4 to 6 mins. per cycle. 5. What is the expected productivity per 8 hr. shift? The productivity shall depend on the speed with which the workmen load grids into the cassette and unload filled plates from the cassette. The min. productivity per eight hour shift shall be in the range of 600 to 800 nos. depending on plate size. 6. How exactly does the dust collector work? The dust collector works very effectively pulling all dust away from the operators. The dust gets collected on the surface of the filter cartridges and clean air is exhausted out to the atmosphere. The blower fan remains ON throughout creating the exhaust draft for the fine lead dust.The dust collected on the surface of the filter cartridges is dislodged by means of reverse pulse jet of air at regular periodic intervals which is controlled by a timer using diaphragm valve. The dust is collected in a container at the bottom of the hopper. This container should be emptied periodically. 7. What exactly does the differential pressure gauge of dust collector indicate? The differential pressure gauge indicates the pressure drop across the filter cartridge elements.This differential pressure is an indicator of the condition of the filter elements. More the differential pressure more the dust accumulated on the filter cartridge. This pressure differential must be normally between 100 mm w.c. and 150 mm w.c. The gauge has a full scale display up to 250 mm w.c. In case the indication exceeds 150 mm w.c. and remains there for long time you must check whether the exhaust flap is fully open. If yes, please close the flap up to 50% or more and check the gauge. In case the gauge indication is not as per recommendations and the suction of dust collector is not efficient / as required remove the filter cartridges, clean it using compressed air and fit it in place again. You can also try OFFLINE pulsing i.e. keep the blower ON for about 30 minutes or so after the production of filling has been stopped for the day. |
Additional Information:
Payment Terms : L/C,
Packaging Details : SEAWORTHY WOODEN BOX FUMIGATION AND CERTIFICATION PROVIDED
