As a supplier of OPZS Battery factory, I am delighted to take you through the intricate production process of OPZS batteries. OPZS (Oxygen Recombinant, Tubular Positive, Separator) batteries are renowned for their long - service life, high reliability, and excellent performance, making them ideal for a wide range of applications such as telecommunications, uninterruptible power supplies (UPS), and renewable energy storage.
Raw Material Procurement
The production of OPZS batteries begins with the careful selection and procurement of high - quality raw materials. The main components include lead, antimony, calcium, and other alloying elements for the battery plates. Lead is the primary material for the positive and negative plates, and its purity is of utmost importance. We source our lead from trusted suppliers who adhere to strict quality control standards.
Antimony and calcium are added to the lead to enhance the mechanical properties and electrical performance of the plates. The separators, which are usually made of porous glass fiber or micro - porous rubber, play a crucial role in preventing short - circuits between the positive and negative plates while allowing the flow of electrolyte. The electrolyte, typically a solution of sulfuric acid and water, is also carefully prepared to ensure the correct specific gravity and purity.
Plate Manufacturing
The first step in plate manufacturing is the production of the lead alloy grids. The lead alloy is melted in large furnaces at high temperatures, and then cast into grid - like structures using precision molds. These grids serve as the framework for the active materials of the battery plates.
The positive plates are tubular, which is one of the key features of OPZS batteries. The tubular design provides excellent mechanical support for the active material, preventing shedding and extending the battery's service life. To make the positive plates, a mixture of lead oxide, sulfuric acid, and other additives is prepared and then filled into the tubular pockets of the grid. The tubular pockets are made of a porous material that allows the electrolyte to penetrate and react with the active material.
The negative plates are made by applying a paste of lead oxide and sulfuric acid onto the flat grids. After the paste is applied, the plates are cured in a controlled environment to allow the chemical reactions to take place and to harden the active material. This curing process is critical as it affects the performance and longevity of the battery.
Assembly of Battery Cells
Once the plates are manufactured, they are assembled into battery cells. The positive and negative plates are interleaved with separators to prevent short - circuits. The plates are then placed into a plastic or fiberglass container, which serves as the housing for the battery cell.
The container is designed to be resistant to the corrosive effects of the electrolyte and to provide mechanical protection for the plates. After the plates are placed in the container, the electrolyte is carefully added. The amount of electrolyte is precisely measured to ensure the correct level and specific gravity.
The cells are then sealed to prevent the leakage of electrolyte and to maintain the internal pressure of the battery. Sealing is a critical step as it affects the safety and performance of the battery. We use advanced sealing technologies to ensure a tight and reliable seal.
Formation and Testing
After the battery cells are assembled, they undergo a formation process. This involves charging and discharging the cells in a controlled manner to convert the lead oxide on the plates into active materials (lead dioxide on the positive plates and sponge lead on the negative plates). The formation process is carefully monitored to ensure that the cells are fully formed and that the active materials are evenly distributed.
Once the formation process is complete, the battery cells are subjected to a series of rigorous tests. These tests include capacity testing, voltage testing, and internal resistance testing. Capacity testing measures the amount of electrical energy that the battery can store and deliver. Voltage testing ensures that the battery operates within the specified voltage range. Internal resistance testing is used to assess the efficiency of the battery and to detect any potential problems.
Battery Pack Assembly
For applications that require higher voltages or capacities, multiple battery cells are connected together to form battery packs. The cells are connected in series or parallel, depending on the requirements of the application. Series connection increases the voltage, while parallel connection increases the capacity.
The battery packs are then installed in a suitable enclosure, which provides additional protection and support. The enclosure is designed to be easy to install and maintain, and it may include features such as ventilation, temperature sensors, and monitoring systems.
Quality Control and Final Inspection
Throughout the production process, strict quality control measures are implemented to ensure that every OPZS battery meets the highest standards of quality and performance. In addition to the testing at the cell level, the finished battery packs are also subjected to a final inspection.
During the final inspection, the appearance of the battery packs is checked for any signs of damage or defects. The electrical performance is also re - verified to ensure that the battery packs meet the customer's specifications. Only after passing the final inspection are the battery packs approved for shipment.
Comparison with Other Battery Types
OPZS batteries have several advantages over other types of lead - acid batteries. Compared to Gel AGM Battery, OPZS batteries have a longer service life, especially in high - temperature environments. The tubular positive plates in OPZS batteries are more resistant to corrosion and shedding, which contributes to their extended lifespan.
When compared to High Rate Battery, OPZS batteries are better suited for deep - cycle applications. They can withstand repeated deep discharges without significant loss of capacity, making them ideal for renewable energy storage systems where the batteries are often cycled deeply.
2V Deep Cycle AGM Battery is another popular type of battery. However, OPZS batteries offer better performance in terms of long - term reliability and maintenance requirements. The oxygen recombination technology in OPZS batteries reduces the need for frequent watering, which is a significant advantage in many applications.
Conclusion
The production process of OPZS batteries is a complex and highly technical operation that requires strict quality control and advanced manufacturing techniques. From the procurement of raw materials to the final inspection of the finished battery packs, every step is carefully monitored to ensure the highest quality and performance.
OPZS batteries are a reliable and cost - effective solution for a wide range of applications. If you are in the market for high - quality energy storage solutions, we invite you to contact us for more information and to discuss your specific requirements. Our team of experts is ready to assist you in selecting the right OPZS battery for your application. Whether you are involved in telecommunications, UPS systems, or renewable energy projects, we can provide you with the best - in - class OPZS batteries that meet your needs.
References
- "Lead - Acid Batteries: Science and Technology" by Thomas M. Vissers
- "Battery Technology Handbook" edited by Andrew Burke