1. MANUFACTURING CONCEPTS
RANABIR CHAKRABORTY

2. WHY STRESS ON CONCEPTS? THE PRESENTATION IS FOR MSME SECTOR.
CHANGED CIRCUMSTANCES IN LEAD ACID BATTERY USE.
UNITS WITH AGE OLD MANUFACTURING PROCESS/PRACTICES.
FACING STRONGER CHALLENGE FROM ORGANIZED SECTOR. PERFORMANCE/COST OF PRODUCT.
DEMANDS OF DEEPCYCLE PRODUCTS SHOOTING UP.

3. ALLOY DEPLETION ON ALLOYING ELEMENTS
LOSS OF SELENIUM,TIN etc – prevention/ master alloy use.
- CORROSION OF GRIDS, TOP LEAD leading to early failure
- DIFFICULT TO DETECT. OES/Good Lab availability.
HIGH ANTIMONY ALLOY ?
HIGH ANTIMONY ALLOY MEANS LESS CORROSION
- DEEP CYCLE BATTERY LIKE FLT USES HIGH ANTIMONY ALLOY
- MOST SUCCESSFUL DEEP CYCLE BATTERY MAKER USES TOO.

4. OXIDE SAME OXIDE BEING USED FOR ALL APPLICATION.
NEED. – AUTOMOTIVE- LOW AD. DEEPCYCLE- HIGH AD
TUBULAR – BETTER WITH POT OXIDE
IMPURITY CHECK IN REFINED RECYCLED PURE LEAD.

5. GRID DESIGN DESIGN TO CORRECT FAILURE PATTERN.
THICKNESS SUITING APPLICATION.
INTERNAL WIRES BELOW FRAME. TAPER WIRES.
LOWER WEIGHTS IN AUTOMOTIVE APPLICATION
TUBULAR WITH THINNER SPINES. Hand/hydraulic

6. PASTE MIXING PASTE DENSITIES MATCHING APPLICATION.
SULPHATE CONTENT DIFFERENT. NOT SAME ACID QTY
USE OF ADDITIVES MATCHING REQUIREMENT
USE OF TBLS IN BOTH FLAT AND TUBULAR POSITIVE
CARBON ADDITIVE ENHANCEMENT IN NEGATIVE
PEAK MIX TEMPERATURE AT 55 DEGREE C
DISPERSION OF ADDITIVES - SIGMA/MULLER ADVANTAGE

7. PASTING PASTE COVER ON BOTTOM SURFACE OF POSITIVES
MACHINES TO UPGRADE/RESTORE.
EFFECTIVE USE OF FINISHING ROLLER
AVOIDING FDO BY SLOWER SPEED USE, IF POSSIBLE
MAINTAIN STEADY PASTE LEVEL IN HOPPER.
9.5% MOISTURE FOR POSITIVE AND 8.5% NEGATIVE BEFORE CURING.

8. CURING AND DRYING UNDERSTANDING MICRO AND MACRO PORES. . o
PRE-CONDITIONING THE OVEN BEFORE USE.
UNIFORM DROP OF RL AND MOISTURE, VERY IMPORTANT.
LOW AIRFLOW DURING CURING.
OXYGEN AVAILABILITY DURING CURING BY AIR INGRESS.
CURING, BONDS GRID WITH ACTIVE MATERIAL.
INCREASE TO DRYING TEMPERATURE IN STEPS TO AVOID CRACKS

9. ASSEMBLEY QUALITY OF JIGS AND COMBS MUST BE ROBUST.
USE OF SMALL PARTS WITHIN 4 HRS TO ICW. ALLOY HARDENS.
RETURN TO POT EXCEEDING ABOVE TIME.
KEEP CHECK ON ALLOY QUALITY

10. CHARGING CHARGING PARAMETERS TO UPGRADE
- PULSE CHARGING WITH CHARGE AND REST-ONE WAY
- TEMPERATURE CONTROLLED STEPPED CHARGING- ANOTHER WAY
- MAXIMISE AH INPUT IN HIGH CHARGE ACCEPTANCE PERIOD
- PILOT CELL MONITORING EVERY HOUR. TEMP.&GRAVITY
TEMPERATURE LIMIT OF 55 DEGREE C FOR ELECTROLYTE
AVOID CHARGING BELOW 40 DEGREE C
END OF CHARGE WITH 3 CONSTANT GRAVITY READINGS

11. TUBULAR
ACID PICKLING. PbO2 TO REACH 60% FOR 60/40 RATIO AND 70% WITH 70/30 RATIO.
AMMONIA DIPPING IS TO CLEAN PLATE SURFACE,COAT SURFACE WITH SULPHATE, MAKE THE PLATE WET FOR CURING. NOT PICKLING.
KEEP IN OPEN 24 HRS FOR CURING. DROP OF RL AND MOISTURE.
6HRS PICKLING CHHARGE IF NO ACID PICKLING OUTSIDE.
FOR AMMONIA PICKLING PLATES, AT LEAST TWO DISCHARGES OF TWO HOURS IS NECESSARY BEFORE 70% OF CHARGE.

12. E- RICKSHAW DAILY FULL CHARGE WITH SOME BUBBLING ESSENTIAL
- PARTIAL STATE OF CHARGE REDUCES LIFE CONSIDERABLY
BATTERIES TO HAVE EASY ACCESS FOR TOP UP.
AVERAGE LIFE IS 9 MONTHS NOW. SOME OF 15 MONTHS
NEED TO INCREASE LIFE CONSIDERABLY – TARGET 2 YEARS SO THAT LEAD ACID BATTERY STAYS.
RANGE IN KM, INCREASES DAILY EARNING.
E- RICKSHAW SPECIAL BATTERIES TO DESIGN

13. THANKS