Product description:
Now a day, automotive battery is also used for IPS, UPS service. The batteries that Rahimafrooz produces are suitable for both automotive and home appliances use. An automotive battery is a type of rechargeable battery that supplies electric energy to an automobile. It is used power the starter motor, the lights, and the ignition system of a vehicle’s engine. An automotive battery may also be a traction battery used for the main power source of a vehicle. Now a day, automotive battery is also used for IPS, UPS service. The batteries that Rahimafrooz produces are suitable for both automotive and home appliances use.
Automotive SLI batteries are usually lead-acid batteries, and are made of six galvanic cells in series to provide a 12 volt system. Each cell provides 2.1 volts for a total of 12.6 volt at full charge. Heavy vehicles such as highway trucks or tractors, often equipped with Diesel engines, may have two batteries in series for a 24 volt system, or may have parallel strings of batteries.
Lead-acid batteries are made up of plates of lead and separate plates of lead dioxide, which are submerged into an electrolyte solution of about 35% sulfuric acid and 65% water. This causes a chemical reaction that releases electrons, allowing them to flow through conductors to produce electricity. As the battery discharges, the acid of the electrolyte reacts with the materials of the plates, changing their surface to lead sulfate. When the battery is recharged, the chemical reaction is reversed: the lead sulfate reforms into lead oxide and lead. With the plates restored to their original condition, the process may now be repeated.
Lead-acid batteries for automotive use are made with slightly different construction techniques, depending on the application of the battery. The "flooded cell" type, indicating liquid electrolyte, is typically inexpensive and long-lasting, but requires more maintenance and can spill or leak. Flooded batteries are distinguished by the removable caps that allow for the electrolyte to be tested and maintained.
More costly alternatives to flooded batteries are "Sealed" or "Valve regulated" battery of the absorbed glass mat (AGM) type which uses a glass mat separator, and a "gel cell" uses fine powder to absorb and immobilize the sulfuric acid electrolyte. These batteries are not serviceable (typically termed "maintenance-free") and do not require replenishment of electrolyte under normal use. Both types of sealed batteries may be used in some automotive applications where leakage is a concern. However, this article deals with the classic, flooded-type of car battery.
The starting (cranking) or shallow cycle type is designed to deliver large bursts of power for a short time, as is needed to start an engine. Once the engine is started, the battery is recharged by the engine-driven charging system. Starting batteries are intended to have a low depth of discharge on each use. They are constructed of many thin plates with thin separators between the plates, and may have a higher specific gravity electrolyte to reduce internal resistance.

Materials required for manufacturingBatteries are made of five basic components: * A resilient plastic container. * Positive and negative internal plates made of lead. * Plate separators made of porous synthetic material. * Electrolyte, a dilute solution of sulfuric acid and water, better known as battery acid. * Lead terminals, the connection point between the battery and whatever it powers. Manufacturing process:Overall manufacturing process is dived into six steps.Rahimafroz designed their manufacturing plant in a systematic way where this six steps are done one by one.They follow the universal manufacturing process. The detail description of what happens in which stage are given below. * Step 1: The manufacturing process begins with the production of a plastic container and cover. Most automotive battery containers and their covers are made of polypropylene. For a typical 12-volt car battery, the case is divided into six sections, or cells, shaped somewhat like one row in an ice-cube tray. The cover is dropped on and sealed when the battery is finished. * Step 2: The process continues with the manufacture of grids or plates from lead or an alloy of lead and other metals. A battery must have positive and negative plates to conduct a charge. * Step 3: A paste mixture of lead oxide which is powdered lead and other materials like sulfuric acid and water is applied to the grids. Expander material made of powdered sulfates is added to the paste to produce negative plates. Inside the battery, the pasted positive and negative plates must be separated to prevent short circuits. Separators are thin sheets of porous, insulating material used as spacers between the positive and negative plates. Fine pores in the separators allow electrical current to flow between the plates while preventing short circuits * Step 4: In the next step, a positive plate is paired with a negative plate and a separator. This unit is called an element, and there is one element per battery cell, or compartment in the container. Elements are dropped into the cells in the battery case. The cells are connected with a metal that conducts electricity. The lead terminals, or posts, are then welded on. The battery is then filled with electrolyte - or battery acid -- a mixture of sulfuric acid and water, and the cover is attached. The battery is checked for leaks. * Step 5: The final step is charging, or finishing. During this step, the battery terminals are connected to a source of electricity and the battery is charged for many hours. When the battery is fully charged, it moves to another line where the case is cleaned, if necessary, and the labels are attached.Layout of manufacturingStep 1
Step 1
The layout that is used by RBL is a product layout.Step 5
Step 5
Step 4
Step 4
Step 3
Step 3
Step 2
Step 2 |
Production process begins with production of the cover and container
Production process begins with production of the cover and container

Manufacture of grids or plates from lead or an alloy of lead and other metals
Manufacture of grids or plates from lead or an alloy of lead and other metals

A paste mixture of lead oxide is applied to the grids

A paste mixture of lead oxide is applied to the grids

A positive plate is paired with a negative plate and a separator
A positive plate is paired with a negative plate and a separator

Charging, packaging and labeling
Charging, packaging and labeling

Production constraints

Any kind of production process has to go through some sort of difficulties. Rahimafrooz has no exception on their production process. They also have to go through some troubles while producing batteries.
Following problems Rahimafrooz has to face during the production process. None of them are that much severe. But they reduce the production efficiency sometimes.

* Shorted cell due to failure of the separator between the positive and negative plates * Shorted cell or cells due to buildup of shed plate material building up below the plates of the cell * Broken internal connections due to corrosion * Broken plates due to vibration and corrosion * Low electrolyte * Cracked or broken case * Broken terminals * Sulfating after prolonged disuse in a low or zero charged state

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