CA1125862A - Radio frequency beam welding of battery terminals - Google Patents
Radio frequency beam welding of battery terminalsInfo
- Publication number
- CA1125862A CA1125862A CA316,518A CA316518A CA1125862A CA 1125862 A CA1125862 A CA 1125862A CA 316518 A CA316518 A CA 316518A CA 1125862 A CA1125862 A CA 1125862A
- Authority
- CA
- Canada
- Prior art keywords
- bushing
- post
- welding
- battery
- radio frequency
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K13/00—Welding by high-frequency current heating
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/543—Terminals
- H01M50/552—Terminals characterised by their shape
- H01M50/561—Hollow metallic terminals, e.g. terminal bushings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Sealing Battery Cases Or Jackets (AREA)
- Connection Of Batteries Or Terminals (AREA)
Abstract
Abstract A novel method for fusion welding a terminal post and cover bushing of an assembled battery cell jar and/or for welding an intercell connector to an assembled post and bushing, including directing a radio frequency energy beam onto the components to be welded while encircling those components with a cooling ring to prevent damage to the battery jar. The result is a deep homogenous weld of improved quality.
Description
Background of the Invention The present invention relates to a novel method ~or fusing or welding the terminals and/or intercell connections of lead-acid batteries, and to apparatus therefor.
It has long been known that bat~ery posts or terminals can be sealed with respect to -the cover or other wall surface through which that terminal is intended to pass by fusing or welding that post to an adjacent sleeve or bushing which is molded into that cover. The resultant weld of the post and bushing seals the battery cell to prevent leakage. In the case of a battery terminal, such as an automotive batkery terminal, no further parts need be welded to the terminal post and bushing. In the case of a motive power battery, or an automotive battery wherein the post and bushing are to be connected to an adjacent cell using an exterior connector, a battery cell connector may be either simultaneously or subse-quently welded to the post and bushing to create an intercell connection between that terminal and the terminal of an adjacent cellO See, for e~ample, the top two drawings of Figure 18 on page 66 of Dr. Georye Wood Vinal's treatise entitled "Storage Batteries: A General Treatise on the Physics and Chemistry of Secondary Batteries and Their Engineering Applications", 4th Edition 1955, John Wiley &
Sons, Inc., which treatise is incorporated by reference as if fully set forth herein.
One standard prior art technique which has been used to assemble a motive power battery is to hand weld the battery terminals. More recently, other methods have been developed for welding battery terminal posts to battery terminal bushings, or otherwise making connections through the wall of a battery cell partition. While these other .
.
5~362 methods have experienced some success r there still exists a need to create a deep homogeneous weld, particularly in industrial or motive power batteries, where the amount o~
current carried by the connector and/or terminal is great and the mass o~ metal to be welded toyether is quite substantial.
Summary of the Invention , ~
Our invention generally relates to a method for using a radio ~requency energy beam to weld the terminal connections and intercell connections of a lead-acid battery through an aperture in a battery cell wall, and more particu-larly relates to the welding of a battery terminal bushing to a battery terminal post disposed therein, while using a heat sink or cooling ring to encircle the weld area.
With respect to the preferred embodiment welding apparatus of the present invention, best results are obtained when the welding apparatus is operated within specific para-meters, described hereinafter. As a result of using the preferred embodiment radio frequency beam welding method of the present invention, superior industrial battery cell terminal connections are produced which are characterized by deep homogeneous dross-free welds between the battery terminal posts and cover bushings.
Brief Descr_ption of the Draw_ngs Figure 1 is an enlarged/ exploded view of a pre-ferred embodiment connector assembly in accordance with the present invention, shown in an exploded relationship with respect to ~ cooling ring used during the welding operation;
Figure 2 is a cross-sectional view of the components illustrated in Figure l;
~5~2 Figure 3 is a diagrammatic view of a preferred embodiment welding head, oriented generally over the -top of an industrial bat-tery as shown, for welding intercell connectors;
Figure ~ is a diagrammatic cross-sectional view of one embodiment of our invention, wherein a cooling ring has been fitted around the bushing and post prior to activ-ation of the radio frequency beam head which is oriented generally along the axis of the post;
Figure 5 illustrates an alternative method of welding a battery post to a cover bushing using a cooling ring fitted thereo~er, and a radio frequency beam head oriented generally axially with the battery post;
Figures 6 and 7 illustrate a cooling ring similar to that shown in Figure 4;
Figures 8 and 9 are side views of the cooling rings illustrated in Figures 6 and 7, respectively, showing the path of the cooling fluid through those rings;
Figure 10 is-a top view of a preferred embodiment double cooling ring for use in producing a battery cell connection involving both positive and negative terminals which are to be simultaneously welded;
Figure 11 is a side view of the double cooling ring shown in Figure 10, also showing the path of the cooling fluid;
Figure 12 is a side view of the preferred embodi-- ment welding station of the present invention showing a vertically movable head which is fitted with cooling rings, beam no~zles, and a network module, and also showing the RF
generator and gas control station which services the head;
Figure 13 is a front View o~ the station illustrated in Figure 12 also showing the water lines, fume ex~aus-t and electric e~e of the preferred embodiment;
Figure 1~ is a top view of the apparatus illus~rated in ~igures 12 and 13 also showing the dual radio frequency beam heads mounted on the vertically movable beam carriage.
Detailed Description of the Preferred Embodiment Referring now to Figure 1, it will be understood that, prior to welding with a radio frequency beam head, asseml~ly of each battery cell jar is required. As described hereinafter, a novel method is provided for use in accomplish-ing this assembly. Basically, a bushing 120 which is either screwed or molded into a cover 121 is pierced by a battery post 122 as shown in Figures 1 and 2 and a cooling ring 130 placed thereover, as will be described more fully hereinafter in connection with Figures 12-14.
Referring now to Figure 3, the general axial orientation of a single radio frequency beam head 123 over a connector 124 of a motive power storage battery to be welded is illustrated. According to one embodiment of the present invention, a radio frequency beam head 123 having a cooling ring 130 mounted in cooperation therewith is axially intro-duced into engagement with each connector 124 to be welded to each "button", indicated generally by the arrow 125, of a sealed battery cell. Alternatively, it is anticipated that with increased power, the battery post 122, bushing 120 and connector 124 can all be welded in a single operation.
Referring now to Figure 4, the preferred axial orientation o~ the radio frequency beam head 123 over the post 122 is shown, and a cooling ring 130 is illustrated as being fitted to encircle the sleeve or bushing 120 and the ~J
5~6~
post 122 contained there~ithin. In Fi~ure 5, a sll~htly different lead flange 126 and battery post 127 are illustrated, and a cooling ring 128 is shown which is adapted to bridge more than one battery post 127 so that a single coolinc~ riny 128 can service more than one radio ~requency beam. While Figures 4 and 5 illustrate traditional rubber cover designs, it is anticipated that "poly" covers and jars will be used and heat sealed in accordance with the preferred embodiment batteries to be produced therewith.
Figures 6, 7, 8, 9, 10 and 11 illustrate various preferred embodiment cooling rings for mounting on the welding carriage 110 of the apparatus 118 shown in Figures 12-14;
Maximum clearance is illustrated between the cooling rings to facilitate welding terminals which are located on either side o~ the fill hole of a battery cell being assembled. In the preferred embodiment, cooling fluid is introduced into and circulated through these cooling rings as shown by the arrows 131 in these figures. In order to maximize cooling efficiency, these cooling rings are preferably composed of aluminum.
Referring now to Figure 12, the preferred embodi-ment welding station 132 of the present invention is illus-trated. A welding carriage, designated generally as 100, i5 adapted for reciprocal, vertical movement along a plurality of rails 133 at the four corners thereof, so that the carriage 100 may be moved downwardly -to engage battery cells which are located on the conveyor 134 and which are maintained ~ in position by retractable rams 102. Located above the cooling rin~s 101 on the carriage 100 are a plurality of beam nozzles 109. These beam nozzles 109 may be of a type generally illustrated in U.S. Patent Nos. 3,894,209 issued July 8, 1975 to Sirius Corporation and 3,648,015 issued ~arch 7, 1972 to Thomas E. Fairbairn.
36~
As defined in the abstract of U.S. Patent No. 3,648,015, each beam nozzle generally comprises "an electron beam torch whose flame is generated by high power ra~io ~requency pro-vided by a modified high fre~uency transmitter. The mechanical structure of the torch is comprised of an electrode held within a metal nozzle, which is attached by means oE a metal tube to a high voltage low current point of the final OUtptlt tank coil of a modified output circuit or amplifier. An amount of inert or other gaseous media is u-tilized to enclose the electron beam torch flame immediately adjacent to the torch nozzle orifice, to (l) provide a shield and focus the ~t flame on the work piece, (2) to cool the torch nozzle and prevent the electrode from melting and oxidizing and (3) to vary the temperature of the work piece."
Disposed above the beam nozzles 109 on the carriage 100, for vertical movement therewith, is network module 104 which is adapted to split and control the radio frequency energy produced by RF generator 106, which is disposed immediately behind carriage frame 108. A control station 110 to control gas flow through the gas lines 111 to the network module 104 is supplied by tanks 112, 114 and 116.
Referring now to Figure 13 which a front view of the apparatus 118 shown in Figure 12~ water lines 113 are shown communicating with the welding carriage 100 for the purpose of providing a coolant to cooling rings 101. Since dissipation of gas in the vicinity of th~ weld is important, it has been found that the axial positioning of the beam nozzles 109 is important to aid in the dissipation of the gas in the vicinity of the weld. Accordingly, an exhaust manifold 103 is provided adjacent to and slightly above the cooling rings 101 such that gas which is dissipating in the vicinity of the weld area 25~
will be carried immediately away from that area and will not interfere with continuing welding operations.
Referring now to Figure 14 which is a top view o~ -the apparatus 118 illustrated in Figllres 12 and 13, the rela~ive orientation of the various components of the apparatus 118 are clearly illustrated. Beam nozzles 109, for example, are shown oriented within a plane traverse to the advancement o~
the conveyor 134, so that adjacent, spaced apart terminals on individual cells may be welded therewith.
Referring to Figures 12-1~, it will be seen that the preferred embodiment welding station 132 of the present construction will simultaneously weld together two terminals on the cell cover 121 to a required weld depth o~ approximately 3/8ths of an inch, and will accomplish cell widths of between 6.25 inches and 8.63 inches and cell heights of between 13.75 to 31.75 inches, the majority of which will be 20.25 inches high. The cells enter the apparatus 118 one at a time, and stop beneath the cooling rings 101 in delayed response to a photo-electric cell 115, shown on the carriage assembly 100. The cooling rings 101 reciprocate above the cover 121 to selectively index against the cell cover bushings 120.
When the cooling rings 101 are properly indexed, twin beams weld the terminals, after which the beams are preferably reduced drastically in energy level, to a point where they will not melt the plastic cover 121 of the jar when moved thereacross (as for example between 0 and 100 watts). Then the cooling rings 101 rise and the cell is moved forward untii two more bushings are indexed into position. For those jars having more than one pair of bushings and terminals to be welded, the machine will index through as many positions as are needed, until each of the terminals have been welded.
6~
The maximum c~cle time is 15 seconds per cell ~or a two bushing cell, and 30 seconds per cell ~or a ~ or 6 ~ushiny cell.
In the preferred embodiment, the beam settinys should be varied in order to accommodate strength, time per weld, gas flow rates, appropriate cooling rinys to Eit corresponding bushings, center-to-center bushing distances, and finally module height adjustment and lock; to insure thak the cooling rings are approximately one-half inch above the bushings.
Based on the data detailed below, and experience gained during testing, it has been found that a 5 kilowatt radio fre~uency beam generated, for example, of the type available ~rom Energystics, Inc., of Toledo, Ohio, is capable of consistently welding two industrial battery terminals, simultaneously, to a minimum depth of 3/8 of an inch. In thls regard, in the preferred embodiment, high quality welding is insured by carefully controlling the beam nozzle design, beam strength and duration, beam distance and position with respect to the point to be welded, post to cover bushing fit, and cooling ring design.
In the preferred embodiment, the beam is oriented vertically downwardly onto the center of-the cell terminal.
The nozzle design and gas flow are chosen to focus and give momentum to the beam in a manner which is sufficient to con-centrate the beam, to push the previously expelled gas away from the area, and to pravent lead oxide vapor from travelling back up the beam and causing the beam to scatter and collapse.
So that the gas and vapor can be expelled properly, a cooling ring is provided which allows for even gas dissipation on all sides~ The use of an aluminum cooling ring to successfully prevent any damage to the plas~ic cover has been found to be ~s~
satisfactory. ~loreover, the preferred embodiment coolin~
ring comprises edges 117 in the weld area which are bevelled in order to prevent beam attraction, so that the beam will not tend to arc to the edge of the ring rather than to the lead parts to be welded. In order to additionally prevent beam arcing, the top surface 119 of the ring is prefera~l~
coated with a layer of ceramic.
It has been found that a maximum gap of 0.010 inches per side (0.020 inches if all on one side) may be toleratea between the post 122 and cover bushing 120. If the post to bushing fit is looser than the above mentioned range, the depth of weld decreases significantly. It is theorized that the heat is not conducting as rapidly to the bushing and/or that if the gap is above 0.020 inches per side~ the beam may arc down the post, in a skin effect, into the cell. By main taining the top surfaces of the post 122 and bushing 120 at equal heights, the depth of weld is maximized.
Accordingly, the following normal operating parameters are recommended for both standard, and 5 anll 7 plate c~ll tenllinals:
1. Gas flow rates - Core (helium) - 17.5 scft/hr -~ 1 Sheath (helium) - 1 scft/hr + 1,-0.5 Sheath (hydrogen) - 5 scft/hr J~ 1
It has long been known that bat~ery posts or terminals can be sealed with respect to -the cover or other wall surface through which that terminal is intended to pass by fusing or welding that post to an adjacent sleeve or bushing which is molded into that cover. The resultant weld of the post and bushing seals the battery cell to prevent leakage. In the case of a battery terminal, such as an automotive batkery terminal, no further parts need be welded to the terminal post and bushing. In the case of a motive power battery, or an automotive battery wherein the post and bushing are to be connected to an adjacent cell using an exterior connector, a battery cell connector may be either simultaneously or subse-quently welded to the post and bushing to create an intercell connection between that terminal and the terminal of an adjacent cellO See, for e~ample, the top two drawings of Figure 18 on page 66 of Dr. Georye Wood Vinal's treatise entitled "Storage Batteries: A General Treatise on the Physics and Chemistry of Secondary Batteries and Their Engineering Applications", 4th Edition 1955, John Wiley &
Sons, Inc., which treatise is incorporated by reference as if fully set forth herein.
One standard prior art technique which has been used to assemble a motive power battery is to hand weld the battery terminals. More recently, other methods have been developed for welding battery terminal posts to battery terminal bushings, or otherwise making connections through the wall of a battery cell partition. While these other .
.
5~362 methods have experienced some success r there still exists a need to create a deep homogeneous weld, particularly in industrial or motive power batteries, where the amount o~
current carried by the connector and/or terminal is great and the mass o~ metal to be welded toyether is quite substantial.
Summary of the Invention , ~
Our invention generally relates to a method for using a radio ~requency energy beam to weld the terminal connections and intercell connections of a lead-acid battery through an aperture in a battery cell wall, and more particu-larly relates to the welding of a battery terminal bushing to a battery terminal post disposed therein, while using a heat sink or cooling ring to encircle the weld area.
With respect to the preferred embodiment welding apparatus of the present invention, best results are obtained when the welding apparatus is operated within specific para-meters, described hereinafter. As a result of using the preferred embodiment radio frequency beam welding method of the present invention, superior industrial battery cell terminal connections are produced which are characterized by deep homogeneous dross-free welds between the battery terminal posts and cover bushings.
Brief Descr_ption of the Draw_ngs Figure 1 is an enlarged/ exploded view of a pre-ferred embodiment connector assembly in accordance with the present invention, shown in an exploded relationship with respect to ~ cooling ring used during the welding operation;
Figure 2 is a cross-sectional view of the components illustrated in Figure l;
~5~2 Figure 3 is a diagrammatic view of a preferred embodiment welding head, oriented generally over the -top of an industrial bat-tery as shown, for welding intercell connectors;
Figure ~ is a diagrammatic cross-sectional view of one embodiment of our invention, wherein a cooling ring has been fitted around the bushing and post prior to activ-ation of the radio frequency beam head which is oriented generally along the axis of the post;
Figure 5 illustrates an alternative method of welding a battery post to a cover bushing using a cooling ring fitted thereo~er, and a radio frequency beam head oriented generally axially with the battery post;
Figures 6 and 7 illustrate a cooling ring similar to that shown in Figure 4;
Figures 8 and 9 are side views of the cooling rings illustrated in Figures 6 and 7, respectively, showing the path of the cooling fluid through those rings;
Figure 10 is-a top view of a preferred embodiment double cooling ring for use in producing a battery cell connection involving both positive and negative terminals which are to be simultaneously welded;
Figure 11 is a side view of the double cooling ring shown in Figure 10, also showing the path of the cooling fluid;
Figure 12 is a side view of the preferred embodi-- ment welding station of the present invention showing a vertically movable head which is fitted with cooling rings, beam no~zles, and a network module, and also showing the RF
generator and gas control station which services the head;
Figure 13 is a front View o~ the station illustrated in Figure 12 also showing the water lines, fume ex~aus-t and electric e~e of the preferred embodiment;
Figure 1~ is a top view of the apparatus illus~rated in ~igures 12 and 13 also showing the dual radio frequency beam heads mounted on the vertically movable beam carriage.
Detailed Description of the Preferred Embodiment Referring now to Figure 1, it will be understood that, prior to welding with a radio frequency beam head, asseml~ly of each battery cell jar is required. As described hereinafter, a novel method is provided for use in accomplish-ing this assembly. Basically, a bushing 120 which is either screwed or molded into a cover 121 is pierced by a battery post 122 as shown in Figures 1 and 2 and a cooling ring 130 placed thereover, as will be described more fully hereinafter in connection with Figures 12-14.
Referring now to Figure 3, the general axial orientation of a single radio frequency beam head 123 over a connector 124 of a motive power storage battery to be welded is illustrated. According to one embodiment of the present invention, a radio frequency beam head 123 having a cooling ring 130 mounted in cooperation therewith is axially intro-duced into engagement with each connector 124 to be welded to each "button", indicated generally by the arrow 125, of a sealed battery cell. Alternatively, it is anticipated that with increased power, the battery post 122, bushing 120 and connector 124 can all be welded in a single operation.
Referring now to Figure 4, the preferred axial orientation o~ the radio frequency beam head 123 over the post 122 is shown, and a cooling ring 130 is illustrated as being fitted to encircle the sleeve or bushing 120 and the ~J
5~6~
post 122 contained there~ithin. In Fi~ure 5, a sll~htly different lead flange 126 and battery post 127 are illustrated, and a cooling ring 128 is shown which is adapted to bridge more than one battery post 127 so that a single coolinc~ riny 128 can service more than one radio ~requency beam. While Figures 4 and 5 illustrate traditional rubber cover designs, it is anticipated that "poly" covers and jars will be used and heat sealed in accordance with the preferred embodiment batteries to be produced therewith.
Figures 6, 7, 8, 9, 10 and 11 illustrate various preferred embodiment cooling rings for mounting on the welding carriage 110 of the apparatus 118 shown in Figures 12-14;
Maximum clearance is illustrated between the cooling rings to facilitate welding terminals which are located on either side o~ the fill hole of a battery cell being assembled. In the preferred embodiment, cooling fluid is introduced into and circulated through these cooling rings as shown by the arrows 131 in these figures. In order to maximize cooling efficiency, these cooling rings are preferably composed of aluminum.
Referring now to Figure 12, the preferred embodi-ment welding station 132 of the present invention is illus-trated. A welding carriage, designated generally as 100, i5 adapted for reciprocal, vertical movement along a plurality of rails 133 at the four corners thereof, so that the carriage 100 may be moved downwardly -to engage battery cells which are located on the conveyor 134 and which are maintained ~ in position by retractable rams 102. Located above the cooling rin~s 101 on the carriage 100 are a plurality of beam nozzles 109. These beam nozzles 109 may be of a type generally illustrated in U.S. Patent Nos. 3,894,209 issued July 8, 1975 to Sirius Corporation and 3,648,015 issued ~arch 7, 1972 to Thomas E. Fairbairn.
36~
As defined in the abstract of U.S. Patent No. 3,648,015, each beam nozzle generally comprises "an electron beam torch whose flame is generated by high power ra~io ~requency pro-vided by a modified high fre~uency transmitter. The mechanical structure of the torch is comprised of an electrode held within a metal nozzle, which is attached by means oE a metal tube to a high voltage low current point of the final OUtptlt tank coil of a modified output circuit or amplifier. An amount of inert or other gaseous media is u-tilized to enclose the electron beam torch flame immediately adjacent to the torch nozzle orifice, to (l) provide a shield and focus the ~t flame on the work piece, (2) to cool the torch nozzle and prevent the electrode from melting and oxidizing and (3) to vary the temperature of the work piece."
Disposed above the beam nozzles 109 on the carriage 100, for vertical movement therewith, is network module 104 which is adapted to split and control the radio frequency energy produced by RF generator 106, which is disposed immediately behind carriage frame 108. A control station 110 to control gas flow through the gas lines 111 to the network module 104 is supplied by tanks 112, 114 and 116.
Referring now to Figure 13 which a front view of the apparatus 118 shown in Figure 12~ water lines 113 are shown communicating with the welding carriage 100 for the purpose of providing a coolant to cooling rings 101. Since dissipation of gas in the vicinity of th~ weld is important, it has been found that the axial positioning of the beam nozzles 109 is important to aid in the dissipation of the gas in the vicinity of the weld. Accordingly, an exhaust manifold 103 is provided adjacent to and slightly above the cooling rings 101 such that gas which is dissipating in the vicinity of the weld area 25~
will be carried immediately away from that area and will not interfere with continuing welding operations.
Referring now to Figure 14 which is a top view o~ -the apparatus 118 illustrated in Figllres 12 and 13, the rela~ive orientation of the various components of the apparatus 118 are clearly illustrated. Beam nozzles 109, for example, are shown oriented within a plane traverse to the advancement o~
the conveyor 134, so that adjacent, spaced apart terminals on individual cells may be welded therewith.
Referring to Figures 12-1~, it will be seen that the preferred embodiment welding station 132 of the present construction will simultaneously weld together two terminals on the cell cover 121 to a required weld depth o~ approximately 3/8ths of an inch, and will accomplish cell widths of between 6.25 inches and 8.63 inches and cell heights of between 13.75 to 31.75 inches, the majority of which will be 20.25 inches high. The cells enter the apparatus 118 one at a time, and stop beneath the cooling rings 101 in delayed response to a photo-electric cell 115, shown on the carriage assembly 100. The cooling rings 101 reciprocate above the cover 121 to selectively index against the cell cover bushings 120.
When the cooling rings 101 are properly indexed, twin beams weld the terminals, after which the beams are preferably reduced drastically in energy level, to a point where they will not melt the plastic cover 121 of the jar when moved thereacross (as for example between 0 and 100 watts). Then the cooling rings 101 rise and the cell is moved forward untii two more bushings are indexed into position. For those jars having more than one pair of bushings and terminals to be welded, the machine will index through as many positions as are needed, until each of the terminals have been welded.
6~
The maximum c~cle time is 15 seconds per cell ~or a two bushing cell, and 30 seconds per cell ~or a ~ or 6 ~ushiny cell.
In the preferred embodiment, the beam settinys should be varied in order to accommodate strength, time per weld, gas flow rates, appropriate cooling rinys to Eit corresponding bushings, center-to-center bushing distances, and finally module height adjustment and lock; to insure thak the cooling rings are approximately one-half inch above the bushings.
Based on the data detailed below, and experience gained during testing, it has been found that a 5 kilowatt radio fre~uency beam generated, for example, of the type available ~rom Energystics, Inc., of Toledo, Ohio, is capable of consistently welding two industrial battery terminals, simultaneously, to a minimum depth of 3/8 of an inch. In thls regard, in the preferred embodiment, high quality welding is insured by carefully controlling the beam nozzle design, beam strength and duration, beam distance and position with respect to the point to be welded, post to cover bushing fit, and cooling ring design.
In the preferred embodiment, the beam is oriented vertically downwardly onto the center of-the cell terminal.
The nozzle design and gas flow are chosen to focus and give momentum to the beam in a manner which is sufficient to con-centrate the beam, to push the previously expelled gas away from the area, and to pravent lead oxide vapor from travelling back up the beam and causing the beam to scatter and collapse.
So that the gas and vapor can be expelled properly, a cooling ring is provided which allows for even gas dissipation on all sides~ The use of an aluminum cooling ring to successfully prevent any damage to the plas~ic cover has been found to be ~s~
satisfactory. ~loreover, the preferred embodiment coolin~
ring comprises edges 117 in the weld area which are bevelled in order to prevent beam attraction, so that the beam will not tend to arc to the edge of the ring rather than to the lead parts to be welded. In order to additionally prevent beam arcing, the top surface 119 of the ring is prefera~l~
coated with a layer of ceramic.
It has been found that a maximum gap of 0.010 inches per side (0.020 inches if all on one side) may be toleratea between the post 122 and cover bushing 120. If the post to bushing fit is looser than the above mentioned range, the depth of weld decreases significantly. It is theorized that the heat is not conducting as rapidly to the bushing and/or that if the gap is above 0.020 inches per side~ the beam may arc down the post, in a skin effect, into the cell. By main taining the top surfaces of the post 122 and bushing 120 at equal heights, the depth of weld is maximized.
Accordingly, the following normal operating parameters are recommended for both standard, and 5 anll 7 plate c~ll tenllinals:
1. Gas flow rates - Core (helium) - 17.5 scft/hr -~ 1 Sheath (helium) - 1 scft/hr + 1,-0.5 Sheath (hydrogen) - 5 scft/hr J~ 1
2. Beam power - true value (total minus reflected) - 4 to 4.5 KW (reflectQd power to be minimized)
3. Beam duration - 9 seconds + 1.
4. Two terminals welded simultaneously by phase sharing of beam.
5. Distance of beam nozzle from top of post and co~er bushing - 0.5 inches ~ .0625".
6. Re~arding beam nozzle to be used, the tip should protrude about 2.5" from the sheath. Tip diameter is about .5625";
sheath diameter is about 1.25". Both sheath and tip must be fully insulated with boron nitrate or molybdenum.
sheath diameter is about 1.25". Both sheath and tip must be fully insulated with boron nitrate or molybdenum.
7. Beam to impin~e on the center of the post, no more than .0625" to any side of the post.
8. Post height should be equal to bushin~ heigh-t, -~.031", - .093".
9. Post to cover bushing fit - maximum gap of .010" per side (.020" i~ all on one side) at the top o~ the post and bushing.
10. Cooling ring fit over exposed top of bushing does not have to be tight. Cooling ring diameter can he up to .0625" greater than bushing outer diameter.
In alternate embodiments of my invention, the beam welding of automotive terminals and bushings is contemplated.
In one such embodiment, tests were run with half an industrial post being tack welded to a partition by a beam angled downward at 45. The energy level and time required were considerably less than that needed for industrial terminal welding, and a beam o~ 250 watts for six seconds was capable of gaining the tack weld described above. In this embodiment, however, the concentration of the beam must be controlled to p~ev~nt melting through the bushing and nto the plastic at the point of maximum direct impingement.
~One approach for preventing such melt through includes varying the duration of the beam to produce a satisfactory weld. By the same token, the positioning of parts to be welded is critical, while the problems with gas dissipation are not as severe as those encountered with industrial battery terminals, as described above. ~ocation of the beam nozzle approximately one inch from the parts to be welded is believed to be satisfactory for this embodiment.
The beam power of 4 to 4.5 kilowatts is presently pre-ferred, however, adequate welds have been obtained using a beam power of as little as 3 kilowattsO
In alternate embodiments of my invention, the beam welding of automotive terminals and bushings is contemplated.
In one such embodiment, tests were run with half an industrial post being tack welded to a partition by a beam angled downward at 45. The energy level and time required were considerably less than that needed for industrial terminal welding, and a beam o~ 250 watts for six seconds was capable of gaining the tack weld described above. In this embodiment, however, the concentration of the beam must be controlled to p~ev~nt melting through the bushing and nto the plastic at the point of maximum direct impingement.
~One approach for preventing such melt through includes varying the duration of the beam to produce a satisfactory weld. By the same token, the positioning of parts to be welded is critical, while the problems with gas dissipation are not as severe as those encountered with industrial battery terminals, as described above. ~ocation of the beam nozzle approximately one inch from the parts to be welded is believed to be satisfactory for this embodiment.
The beam power of 4 to 4.5 kilowatts is presently pre-ferred, however, adequate welds have been obtained using a beam power of as little as 3 kilowattsO
Claims (22)
- The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
l. In a lead-acid battery, a method of welding a battery terminal post to a battery cover bushing comprising the steps of:
(a) providing a battery cover having a lead-alloy bushing sealed in an aperture defined therein;
(b) encircling at least a portion of a battery post with that bushing;
(c) encircling at least a portion of the battery cover bushing with a cooling means; and (d) directing a radio frequency energy beam emanating from a source spaced away from the post and bushing through an aperture defined in said cooling means to weld said bushing to said post. - 2. The invention of claim 1 wherein said radio frequency energy beam is oriented along the axis of said post and said bushing.
- 3. The invention of claim 2 wherein said battery cover is a thermo-plastic battery cover.
- 4. The invention of claim 1 wherein the step of welding said bushing to said post comprises the application of between 2 and 5 kilowatts of radio frequency energy.
- 5. The invention of claim 4 wherein said energy is directed for a period of time which ranges between 5 and 12 seconds.
- 6. The invention of claim 1 wherein a plurality of bushings and posts are simultaneously welded by a plurality of radio frequency beams.
- 7. The invention of claim 1 wherein said cooling means are fluid cooled.
- 8. The invention of claim 1 wherein the beam duration used for welding said bushing to said post is 8-9 seconds.
- 9. The invention of claim 1 wherein said beam impinges upon the center of the post no more than 0.0625 inches to any side of the post.
- 10. The invention of claim 1 wherein the post to cover bushing fit has a maximum gap of 0.010 inches per side (0.020 inches if all on one side) at the top of the post and bushing.
- 11. The invention of claim 1 wherein the cooling means is a cooling ring having an interior diameter which is no greater than 0.0625 inches greater than the bushing outer diameter.
- 12. An apparatus for welding battery cover bushings to battery posts of lead-acid batteries comprising:
(a) a frame;
(b) a supporting surface for supporting at least the bushings and posts to be welded;
(c) a welding carriage transversely movable with respect to said surface, said welding carriage having mounted thereon at least one radio frequency energy beam nozzle and at least one cooling ring, whereby said cooling ring may engage a properly positioned bushing disposed thereunder upon movement of said welding carriage. - 13. The invention of claim 12 wherein said radio frequency energy beam nozzle is axially oriented with respect to the path of movement of said welding head.
- 14. The invention of claim 12 wherein said work surface orients said bushing and said post in an axis parallel to the axis of movement of said welding head.
- 15. The invention of claim 12 wherein said work surface further comprises means for indexing said bushing for encirclement by said cooling ring when said welding head is moved to the welding position.
- 16. The invention of claim 15 wherein said cooling ring is fluid cooled.
- 17. The invention of claim 16 wherein said welding head further comprises an exhaust manifold for exhausting gases from the vicinity of the bushing and post to be welded.
- 18. In a lead-acid battery, a method of welding a battery terminal post to a battery cover bushing comprising the steps of:
(a) providing a battery cover having a lead alloy bushing therein;
(b) arranging said cover so that said bushing is juxtaposed with a post extending from said battery;
(c) providing a heat sink means engaging said bushing;
and (d) welding said battery terminal post to said battery cover bushing by radio frequency energy beam means. - 19. The invention of claim 18 wherein said heat sink means embraces said bushing.
- 20. The invention of claim 1 wherein the height of said post is substantially equal to the height of said bushing, within a range of tolerances between +0.031 inches over to -0.093 inches under the height of said bushing.
- 21. The invention of claim 1 which further comprises preventing beam attraction and arcing to the edges of the cooling means by bevelling the edges of the cooling means in the vicinity of the post and bushing.
- 22. The invention of claim 1 which further comprises preventing beam attraction and arcing to the cooling means by coating the top surface of the cooling means with a ceramic layer.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US85336477A | 1977-11-21 | 1977-11-21 | |
| US853,364 | 1977-11-21 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1125862A true CA1125862A (en) | 1982-06-15 |
Family
ID=25315831
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA316,518A Expired CA1125862A (en) | 1977-11-21 | 1978-11-20 | Radio frequency beam welding of battery terminals |
Country Status (4)
| Country | Link |
|---|---|
| JP (1) | JPS5485346A (en) |
| CA (1) | CA1125862A (en) |
| DE (1) | DE2850499A1 (en) |
| GB (1) | GB1603797A (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4523068A (en) * | 1983-09-19 | 1985-06-11 | Gnb Batteries Inc. | Apparatus and method for fusing battery terminals |
| US5834743A (en) * | 1996-11-19 | 1998-11-10 | Gnb Technologies, Inc. | Induction heating apparatus and method for fusing intercell connectors to battery cell terminals |
| CN111667962B (en) * | 2020-05-19 | 2022-07-22 | 蚌埠市欧利特电子科技有限公司 | Resistor with good heat dissipation performance |
-
1978
- 1978-05-30 GB GB24098/78A patent/GB1603797A/en not_active Expired
- 1978-11-20 CA CA316,518A patent/CA1125862A/en not_active Expired
- 1978-11-21 DE DE19782850499 patent/DE2850499A1/en not_active Withdrawn
- 1978-11-21 JP JP14291378A patent/JPS5485346A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5485346A (en) | 1979-07-06 |
| DE2850499A1 (en) | 1979-05-23 |
| GB1603797A (en) | 1981-11-25 |
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