Note: Descriptions are shown in the official language in which they were submitted.
In both the indirect and direct heat applications
relating to welding mechanisms for forming terminal posts for
batteries, a novel molding means i5 described comprising a
structural member composed of aluminum or other high heat trans
fer material, which is adapted to interchangeably engage an
aluminum mold member which mates with the structural housing and
which actually forms the voids in which th~ melting and castincJ
processes ta]ce~place. The mold members, which are aIso composed
of aluminum or other high heat transfer material, are provided
with a novel mold coating consisting essentially of aluminum
oxide formed through an anodization process. This novel mold
coating is disposed on the surfaces of the mold members which
define the molding voids, and act as a thermal barrier to cause
momentary delay of heat transfer from the melted terminal posts
to the remainder of the mold members and their associated struc-
tural housings. This novel mold coating is described as having
superior release characteristics, while facilitating the forma-
tion of high quality battery terminal posts.
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sackground OL -the Invention
The present invention relates generally to the field
of battery post forming and/or burning, and more particularly,
to the field of burning battery posts with battery cover bushings
for the purpose of forming an integrally fused battery terminal
on the outer surface oE the battery ca.se. This invention, there-
fore, relates ~o weldin~ in general, and speci~ically, for weld-
ing battery terminal posts, as -Eor example, the type of battery
terminals used in automobile batteries.
In welding of vaxious members together, it is common~
place to use a welding rod having flux therein, for many types
of welding, such as arc welding. In other instances, particular-
ly when the materials being welded together are soft, such as h
those comprising pot metal, lead, lead alloys, or like materials,
welding may be effected by ~pplication of open flame to members
that are to be welded together. In many instances, such tech-
niques are highly desired and quite meritorious, however, in
some instances, as for example, when electrical conductivity
is desired, it becomes paramount that the connection between
members beiny welded be such as to create minimal electrical
resistance.
In the manufacture of electric storage batteries, such
as the lead acid batteries normally used in automobiles, groups
of battery plates and separators contained in separate cells ln
a battery case are placed in the case, after which time the
various cells are joined in any of a number of ways to form
intercellular connections therebetween. At the end of the stor-
age battery, slender battery posts which will form the positive
and negative terminals of the battery extend above the upper
surface of ~he open battery case. These battery cases, which
.
are normally composed of polypropylene or other plastic material,
are adapted to receive thereon a polypropyl~ne battery cover,
which has formed therein two lead bushings adapted to be pierced
by the battery posts when the cover is fitted onto the top of
the case. A liquid-tight seal is then formed between the battery
case and battery coverl either by gluing, ultrasonic weldiny, or
by heat sealing means, and the final mechanical assemhly is com-
pleted by Eusing the battery post elements with the battery cov-
er bushing elements to produce the desired positive and negative
battery terminals.
Following the burning of the battery bushing elements
and battery post elements to form positive and negative terminals
on the battery, acid filling, forming and other operations~ may
be conducted in order to produce a finished battery. Consequent-
ly, the burning process for forming integral~ leak-proof battery
terminals is only one step in the assembly of the complete
electric storage battery.
The present invention also relates to the art of pro-
ducing intercellular ccnnections between pluralities of cells
2~ within a battery. In each cell, there are disposed a plurality
of parallel but spaced plates, each having a lug e~tending there~
from, with various lugs keing interconnected by a battery strap,
by any suitable means, such as that disclosed in United States
Patent No. 3~395,748. Extending from a strap of this type,
which connects plates of a given cell, is a post. Adjacent cells
in a given battery are separated by cell partitions. Posts or
groups of plates and adjacent cells must he connected for elec-
trical conductivity between the cells. Accordingly, it is also
this connection of adjacent battery cell posts that is of inter-
est in this application.
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Because of the presence of the cell parti~ion betweenthe posts, the posts are somewhat spaced at their upper end, in
that the posts e~tend generall~ upw~rdly above the height of the
cell partitions, such up~ard extensi:on or protrusion facilitating
the application of heat thereto, for obtaining an eIectrical
connection between the posts across the upper end o e an associ.-
ated plate~ Because the necessity of o~taining good electrical
conducti~ity across such post connections, the' art of ~elding
battery posts has become highly de~eloped r with individuals fo~
performing the same havin~ developed a high degree of skill ~ith
respect thereto.
In weIding battery post~, ei'.ther during the fusing
process ~ith battery cover bus:hi:ng eIements or ~ith adjacent
posts, it is possible to use a gas-~xygen torch or the like, of
an intensity which will permit the delivery of sufficiently
high temperature to the eIements. to be'joined, whi:le at the same
time preventing the matexial at the'upper end of the posts
closest to the flame rom reaching excessive temperatures, s.uch
that early metal 10w from the upper ends of the posts commences,
such flo~ continuing do~n into the space between the'posts and
bushings and/or bet~een the two posts above the separator plates
and solidifyin~ there, before lo~er ends of the posts in the
vicinity of the upper end of the separator plate and/or at the
base of the bushings ha~e become suicientIy heated~ thereb~
resulting in an incomplete fusi:on of metal at a locati.on corres-
ponding to the base o the battery termlnal to be formed and/or
at the upper edge of the cell partition. Thus, the result i5
that while a good fusion may exist at the upper ends of the weld,
often, at the lowermost ends of the ~eld the fusion is imperfect,
with insufficient bond to provide sufficiently low electrical
resistance as a connector~ In order to avoid this, an Gperator
may play the torch bet~een the ~arious elements to be welded,
however, particularly in the case of the polypropylene battery
cover, it is not possible to hold the torch in close proximit~
to that battery cover for fear that the battery c~ver will be~
come scorched or damaged around its junction with the bushin~.
Accordin~ly, the results of weldin~ battery terminals often
results in variations Qr lack of un~formit~ in weId~ent$ t de-
pending upon the particular operator or ~eIder involved~ as well
as resuIting in an undes~rahle percentage of re-
jects due to welds that have a sufficiently goQd
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external appearance to pass customary quality controls, but
which are really poor weldments. Furthermore, since the
appearance of battery terminals, unlike intercel]ular
connections, are available for visual inspection by the intended
consumer, even if a weld of high electrical integrity i.s formed
by the process, the battery is likely to be rejected if the
resulting battery terminal lacks a solid, uniform appearance.
S~mary of the Invention
The present invention is directed towards overcoming
the above and other dif~iculties in connecti.on with the welding
of battery terminal posts, as well as with welding in general~
by providing novel apparatus whereby adjacent members, such as
battery terminal posts and battery cover bushings, may be
welded.
To this end the invention consists of an automated
apparatus for sequentially forming integrally fused battery
terminal.s on a plurality of storage batteries, each o-f which
comprises at least one battery post element and adjacent
battery bushing element, said apparatus comprising: (a) a
frame, (b) head means associated with the frame and movable
with respect to said frame along a first axis between standby
and molding positions, said head means having mold means
mounted thereon to matably encircle bat~ery elements of a
battery in a battery fusing position when said head means is
in said molding position, ~c) burning means capable of
selectively producing a flame -for melting said battery elements
when in a burning position, said burning means being mounted
in slidable engagement along said first axis on sald head
means, for movement with respect to said head means between
a first pilot and a second burning position.
In the preferred embodiment of the present invention
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the head means is movable alon~ the vertical axis, having
mounted thereon the mold means which is adapted to matably
encircle the battery bushing element and battery post element
to be fused, and to act as a mold when the head means is in
its molding position along that axis. The burning means is
capable of producing a variable intensity ~lame ~or preheating,
melting and post warming said battery elements and is mounted
in slidable engagement on said head means. The heat which is
applied thereby is automatically modulated not only by the
proximity of the burning means as it moves towards and away
from the battery elements to be melted, but also by a pre-
selected variation o-f the intensity of the flame produced by
the burning means, which variation is produced as the burning
means moves between the pilot and the burning position. The
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novel flame regulation of the p~eferred embodiment of the
present invention is accomplished through the use of a fixed
trip member mounted on the head means, which cams with a lever
means which is adapted to regulate the gas flow o-f the burner.
Consequently, by reason of movement and the variable flame
intensity described above, applicant has provided modulated
heat application which produces an e~tremely uni:Eorm battery
terminal.
In the preferred embodiment a novel conveyor means
is also provided which is adapted to sequentially store and
move batteries from a first hold position to a second operating
position. This conveyor means further provides clamp means
for transversely forcing each of said batteies into a battery
element fusing position with respect to the vertical axis of
travel of said burning means and said mold means. A feed
sensing means is mounted on the apparatus for sensing the
longitudinal advancement of a battery from the hold position
towards the operating position, and -for causing the stop means
to move -from ~he normal position which does not impede the
longitudinal movement of batteries to the stop position
wherein batteries are halted at said hold and operating
positions. The feed sensing means further causes the movement
of the clamp means from its retracted to its clamped position
in timed response to the sensing of the longitudinal movement
of batteries. An alignment sensing means then determines the
movement of the clamp means to the fully clamped position, and
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causes a cylinder means to move a head means from its standby
to its molding position, wherein molds whlch are adjustably
mounted on the head means, ma~ably encircle said battery elements
to define a void therearound of the shape of the desired battery
terminal. As the head means moves to the molding position,
an abort means senses the lack oE a battery in the battery fusing
position, as might occur where a battery has been manually re-
moved or where the apparatus has otherw;.se malflmctioned. This
abort means then overrides the rè~ai.ning portion of the operating
cycle of the apparatus, preventing the flame from firing and
causing the head means to return to the standby position and the
stop means to move from the stopped to the normal position so
that the next battery may be introduced into the apparatus.
Alternatively, battery sensing means are provided
to determine the presence of a bat-tery in the fusing ~osition
when the head means assumes the molding position, which battery
sensing means causes a hydraulic cylinder to move the burning
means from its pilot to a burning position. As described above,
the burning means further comprises a lever means for contacting
a trip member fixedly engaged on the head means~ thereby automat-
ically regulating the intensity of the flame from a minimum
pilot flame ~hen the burning means is in the pilot posi~ion to
a maximum when the burning means is in the burn positiQn. As
a result, as the burning means moves towards the elements to be
fused, the intensity of heat administered to those elements
increases as the result of the proximity of the flame to those
element~, and also by reason of the intensity of that
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flame. Upon movement of the burning means to the burning
position, a travel sensing means determines the presence of
said burning means in that burning position and causes the
aforementioned hydraulic means to immediately begin moving
the burning means back to said pilot position. The afore-
mentioned trip member and lever means siJnilarly respond to
the retraction of the burning means by gradually reducing the
intensity of the flame to its pilot condition. As a result
of this novel burner action, the battery elements to be fused
are preheated prior to melting, which preheating helps to
eliminate the production of a cold joint such as might occur
had the high intensity flame initially been directly applied
to the cold battery elements. During the melting portion of
the cycle, the high intensity flame is in close proximity
to the elements, causing the complete melting thereof. Finally,
as the torch carriage returns towards the pilot position, a
post-heating phase o-f the cycle occurs which prevents the
outer surfaces of the terminal from prematurely cooling,
thereby creating a puddling effect on the top of the melted
terminal which produces an even, uniform terminal. As a re
sult, the novel burning cycle of the present invention pro-
duces a fused joint which is extremely even and in which
there is little or not layering or antimony precipitation.
There follows a detailed description of embodiments
of the invention as illustrated in the accompanying drawings.
~rief Description of the Drawings
Fig. 1 is a side elevational view of an apparatus for
welding battery terminal posts in accordance with an embodi-
ment of the present invention, showing this embodiment dis-
posed above a battery that, in itself, is partially illustratedin section for clarity of illustration, with the battery being
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disposed on a conveyor;
Fig. 2 is an enlarged fragmentary transverse view of
a portion of the apparatus illustrated in Fig. 1, taken
generally along the lines 2-2 of Fig. l;
Fig. 3 is a further enlarged fragmentary sectional
view~ taken through an embodiment of the heat applying devices
of this invention, taken generally along the lines 3-3 of
~ig. 2;
Fig. ~ is a perspectlve view of some of the welding
apparatus illustrated in Fig. l;
Fig. 5a is a fragmentary view of a pair of upstanding
battery posts with a ~ell partition between adjacent battery
cells being disposed therebetween;
Fig. 5b is a fragmentary view of the pair of adjacent
battery posts of Fig. 5a, with a template disposed thereover,
and with a welding element received within the template, at
- the lower end of its stroke of penetration of liquified post
portions;
Fig. 5c is a fragmentaxy view of portions of the
illustration of Fig. 5b, at a later stages 7 after withdrawal
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of a weldin~ element from the void in the template in which the
liquid mass will be molded into solid formi
Fig. 5d is a fragmentary transverse view of a completed
weld of battery posts of adjacent cells, welded across a parti-
tion, and with a battery cover beina fragmentally illustrated
in phantom disposed thereover, in order to hest illustrate the
manner in which a cover may accurately fit over an accurate and
uniform battery post welded in accordance with this invention;
Fig. 6 shows an assembled view of an alternate illus-
trative embodiment of the principles of the present inventionwhich features flexibly adjustable locations for the heating
elements and also a flexible template system;
Fig. 7 shows a cutaway of a portion of the Fig. 6
apparatus;
Fig. 8 shows in cutaway a variab]e position template
embodying the principles of the present invention;
Fig. 9 shows an overlaying plate to regulate the posi-
tion of the heating elements, as desired;
Figs. lOa through lOd show the operation of the appara-
tus of Figs. 6 through 9 to secure terminal posts to bushingstherefor;
Fig. 11 is a front view of an apparatus for burnin~
battery terminal posts and battery cover bushings in accordance
with the preferred embodiment of the present invention;
Fig. 12 is a perspective vie~ of a portion of the
moldin~ and burning apparatus as illustrated in Fig. 11;
Fig. 13 is a greatly enlarged cross section of the
portion of the apparatus shown in Fig. 12, taken as indicated
by the lines and arrows 13-13 in Fig. 12; and
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Fig. 14 is a schematic representation o~ the various
sensing means of the preferred embodiment of the present inven-
tion shown in association wi~h a front elevation of an apparatus
in accordance with the preferred embodiment of the present inven-
tion, similar to that shown in Fig. 11.
Detailed Description of the Drawings
Although specific forms of the invention have been
selected for illustration in the drawings~ and the follow.ing
description is drawn in specific terms for the purpose of des-
cribing these forms of the invention, this description is not
intended to limit the scope of the invention which is defined in
the appended claims.
Referring now to the drawings in detail, reference is
first made to Fig. 1, and particularly to the lower end thereof,
wherein there is illustrated a battery, generally designated by
the numeral 10, disposed u~on a conveyor 11l having a plurality
of transverse rollers 12 for movement of the battery 10 from
left to right as viewed in Fig. 1, across the rollers 12.
A plurality of cells (six in number), such as those 13
and 14, are illustrated, in which are disposed a plurality of
plates 15 extending downwardly from plate straps such as those
16 and 17, the plate straps 16 and 17 having been already con-
nected to the plates 15, by any suitable means, such as that
described in U.S. Patent No. 3~395~748r or by any other means.
The cells 13 and 14 are separated by suitable cell
par~itions 18, constructed of an inert material, such as plastic
or rubber (due to the presence of battery acid within the cells
13, 14, etc.). The partition 18 extends vertically upwardly
between posts 20 and 21 of adjacent cells 14 and 13, respectively,
. .
with the partition 18 terminating at its upper end short of the
upper ends of the posts 20 and 21~ leaving a space 22 therebetween.
It is this space 22 that, upon welding by the use of
open flame being applied to posts 20 and 21, may become filled
with molten or liquid lead ~or other post material) from the
upper ends of the posts 20 and 21, and flow downwardly to solicl
ify in the space 22 just above the separator plate 18, without
application of a proper amount of heat to those portions of the
posts 20 and 21, below the upper ends thereof as illustrated in
Fiy. 5a, in the vicinity of the upper end of the cell partition
18.
A template 23, constructed of some material ~preferably
metal) having a melting point substantially in excess of that of
the material of the posts 20 and 21, is provided, on the~battery-,
at the upper ends thereof, as illustrated in Fig. l, with pairs
of posts 20 and 21 extending upwardly through voids 24 therein~
It will be clear that the voids 24 extend entirely through the
template 23, and that the voids 24 comprise central portions 25
of a desired size and configuration corresponding to the posts,
to easily receive and contain the same.
The upper and lower ends of the voids 24 are counter-
sunk as at 26 and 27, to permit reception of posts 20 and 21
through the lower ends 27 of the voids 24, and to provide a
dished portion 26 at the upper end of each void 24, to accommo- -
date the recep-tion of molten metal during the welding operation,
with ~he lower countersink or cut-away portion 27 also facilitat
ing the removal of the template 23 after the welding operation i5
complete~ with the weldments solidified. It will further be
noted that the templete 23 is received on the upper lip of the
30 casing 28 o~ the battery 10, as illustrated in Fig. 1.
With particular reference to Fi~s. 5a, 5b and 5c, it
will be seen that a heated element 30 that has been heated by
means later to be described herein, to a temperature sufficient
to melt the upper ends of posts 20 and 21 of ad~acent battery
cells, across the top of a partition 18, is lowered into engage-
ment with the upper ends of the posts 20 and 21, and proceeds .
to melt the same, into a li~uid state, and then to continue its
downward movement, penetratincJ thè li~uid portions o:E the posts
members 20 and 21 being pro~ressively melted as the element 30
moves downwardly, throughout a predetermined vertically downward
stroke of movement of the element 30, such stroke al~o including
a dwell time at the lower end thereof, as illustrated in Fig. 5b,
if desired ~but such dwell not being required), followed by re-
traction, or vertically upward movement of the element 30, in the
direction of the arrow 31 illustrated in Fig. 5c, whereby the
mass of liquid melt displaced into the zone 26 of the templet 23
during that portion of the operation illustrated in Fig. 5b, is
free to fill the zone 25 of the void 24 of the templet 23, above
the upper end of the partition 18, as illustrated in Fig. 5c, for
cooling and solidification of the melt in the zone 25. I~ will
be noted that a plurality (five in numberj of such elements 30
may be utiliz~d simultaneously, in order to simultaneously effect
flve different welds, between posts of adjacent battery cells,
or in fact any desired number of SllCh weldments may be effected,
for battery ce].ls, or for any other purpose, by the above-men-
tioned method of maintaining a constant temperature for the
element 30 and delivering such temperature completely throughout
the zone of the posts 20 and 21, or other members, in which the
weldment is desired.
Furthermore, it will be noted that the voids 2~, and
particularly the central portions 25 thereof, comprise molds for
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the welds, during solidification and cooling thereof. After
the welas are solidified, the templet 23 may be removed from
the casing 28 of the battery 10, for reuse, as desired.
With particular reference to Fiq. 5d, it will be
apparent that a battery cover 32, having an annular cylindrical
protrusion 33, for each pair o~ battery posts welded together,
may be disposed over the upper end of the battery, with each
weld 34 being received within a corresponding annular protrusion
33, for purpose of aligning the battery cover 32, if desired, and
for facilita-ting the covering of the welds 34 and retention of
the cover 32 on the battery 10.
It will further be noted that the welds 34 are simul-
taneously effected, for a given battery, and are all uniform, as
regards their electrical qualities, and as regards their general
height and other physical charac-teristics. Particularly as
regards the height of the same, it will be noted that, all being
of the same general height, the battery cover 32 will more easily
fit thereover, with posts having welds 34 at the upper ends there-
of, all being uniformly received in uni-formly sized annular pro-
trusions 33 of the covers 32.
Referring now to the welding apparatus of this inven-
tion specifically illustrated in Figures 1 through 4, it will be
seen that an apparatus 40 is presented, for carrying a plurality
of heating elements or heat sin]cs 30 protruding outwardly (down-
wardly) from the lower end thereof.
The apparatus 40 comprises a post 41 of cylindrical
configuration, connected by any suitable means, such as tbreading
or the like,as at 42, through a manifold head 43, and throu~h
a base member 44/ to be secured by means of a nut 45 therebeneath.
The base member 44 is of channel-like construction, being gener-
,y~ _
ally of inverted U~shape in transverse cross s.ectional config-
uration, as best illustrated in FigsO 2 and 4. The ~anifold
head 43 is secured to the upper end o the base 44, by any suit-
able means, such as screws or the like. The'manifold head 43
is provided ~ith a pair of conduits 46 and 47 extending longi-
tudinally therethrou~hr' each connected at one end to an associ.ated
gas distri~ution conduit 4~ or 50, provided with associated on-
off inlet valves 51, as desired~ The conduit~ 48 and 50 are
connected to suita~le sources o~ gases-, such as natur~l gas. and
oxygen, respectively, or any othex gases that will facilitate
and support combustion at the desired temperatures. Thus~ ace-
tylene gas may replace the natu~al gas If desired, as may a
mixture of other gases, such as air, repIace the oxygen, if
desired.
The le~t-most end of each.of the manifold channeIs 46
and 47 is closed, as blind conduits (.not illustrated)~
Five eIement heatIng means generally designated each
by the numeral 52, are providedr each.of substantially i.dentical
construction, so ~hat onl~ one need he de~scri~ed in detail ! and
each of which is carried at the lower end of the base member 44,
by a suitable horizontal plate.'53, secured by means o~ a cap
headed scre~ 54 or the like extending therethrough, in engasement
~,
~ithin a nut 55 disposed within the hase 44~ Thus, the'pos~tlon
of any given eIement heating means 52 may be altered by loosen-
ing the screw 54, and r~positioning such:desired ele~ent heating
means, by moving the'plate 53 longitudinally o~ the b.ase member 44.
Each of the heating means 52 is constructed as an ln-
dependent torch, being provided at its upper end ~ith a mixing
device 57, having upper inlets 58 and 60 for recei:vin~, for
example, gas and oxygen therein from respectively asscciated
LQ
hoses 61 and 62 that, in turn, are respec-tively connected to
associated manifold ducts 46 and 47, for supplying gas and oxyyen
to a chamber 63 disposed within the device 57, in which they are
mixed.
Accordingly, the inlets 58 and 60 communicate respect-
ively w.ith the chamber 63. A pair of needle adjustments 64 and
65 are provided~ associated with respective inlets 58 and 60,
each comprising a thumb screw or the like 66, operative through
. a boss 67 in threaded engagament with the device 57 at 68, for
adjusting the position of a needle 70 in the associated inlet,
Eor regulating the amount of gas to be mixed with oxygen, and
the converse~ Upon arriving at a desirable gas-oxygen mixture,
the mixture passes through the conduit 71, to discharge from the
device 57, through a distribution line 72~ that in turn is con-
nected to an element holder 73, by suitable nuts 74 or the like
in threaded engagement with. threads 75, wherein the delivery
lines 76 is bifurcated at 77, into a pair of delivery lines 78
and 80 that are inwardly bent at the lower ends, and have noz-
zles 81 and 82 respectively carried thereby, in the vicinity of
the upper ends of the elements 30, for heating the elements at
a location spaced above the lowermost, or free ends thereof.
The elements 30 are contained within bores or recesses 83, by
suitable screws 84, for eas:e of replacement.
Thus, the application of open flame due to the elimin-
ation of gas and oxygen from nozzles 81 and 82, to the elements
: 30, will heat the elements 30 as aforesa~d~ It will be noted
that elements 30 may also be heated by induction heating (not
illustrated), or by other suitable means, if desired. Tn any
event7 heat is built up and ~tored in the element 30, and in
order to facilitate this end the element 30 may be constructed
of a high temperature alloy, ceramic, or any other suitable
)~
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material. It will be noted that the flame may continually be
applied to the element 30 during the descent thereof and its
retraction, as illustrated in Figures 5b and 5c, throughout its
engagement with and projection into the material of the battery ~).
posts 20 and 21, if desired, or the heat may be applied to the
elements 30 only when tha same are in their uppermost or retract-
ed positions, as desire.d. In any event, there will be a transfer
of heat from the elements 30 to the upper ends of the battery
posts 20 and 21, that will ~e constantly replenished by the
application of heat to the elements 30, by virtue of the appli-
cation of open flame thereto as descrihed above, or by induction
heating, or the like. Furthermore, it will be noted that the
heating elements or tips 30 may take on various desired physical
configurations and sizes, dependin~ upon the particular appli-
cation.
Another feature of this invention resides in the use
of a plate 90 secured to the member 44, by a pair of screws such
as 9l and 92, for eas~ of removal of the same, with the plate
90 having a plurality of openings, voids, notches or the like,
disposed in a uppermost set 93, and a lowermost set 94. The
lowermost set 94 i5 arranged to accommodate plates 53, in accord-
ance with a desired predetermined spacing of element 30 relative
to each other, as measured horizontally, and relative to
posts 20 and 21 of a battery lO to be welded therebeneath,
and also relative to the templet 23'mounted on:the battery lO
and disposed therebeneath. Accordingly, placement of.,the plates
53, in desired ones of the notches 94, will readily accurately
position the elements 30, in accordance with the desired position
for welding the posts of a given battery, for example. However,
the assembly illustrated in Fig. 4 may readily accommodate an
alternative placement of the elements 30, by me~ely removing the
... . _
plate 90, and in~erting the same such that the`'n~tches ~3 are
disposed do~m~ardly, whe~e~y another place~ent of the element 30
relative to each other may readily be effected quickIy and
economically, with minimum set-up t~me~
With particular reference to Firr. l,,it will be noted
that the rod 41 is either mounted to, or comprisesj the piston
rod of a piston (not-shown~, disposed within a piston cyli.nder
96, mounted on suitable :Er~me'97~ The cylinder 96 is provided
~ith suitable fluid inlets 9g and 10~, respecti~eIy, for pxovid-
ing a down~ard driving force, for lowering the element~ 30, orfor retracting the same r depending upon the'p~siti.on o~ the two
way valve 101. It will be noted th.at th.e fluia suppliPd through
the lines 98 and 100 may ~e'any de~ixa~le hydraulic, pneumatic
fluid or the like, and that the piston within the' cylindex 96
would be dri~en either upwardly or downwardly~ dependin~ upon
the setting of the valve'101.
It ~ill be noted that the'stroke'of the piston con-
tained within the cylindex 96 i,s. controlled to automatically
re-set the valve, upon the piston disposed therein reaching, the
lo~er end of a predetermined stroke, in order that th:e elements
30 may be retracted prior to strikin~ the sepa~ator plates. or
partitions 18. ~Iowever, in the event oE misalignment of elements
30 relative to posts 20, 21, or rel'ative to the te~plate 23,
or relative to anything else wherein it is desired t~ prevent
a ~triking of the same by the eIement 30, or even i.n the e~ent
that a battery 10 is raised, :Eox example r at one end~ due to the
presence of a foreign item ~etween the lower end of the ~attery
and the conveyor rollers 12, such that the battery is "cock.ed'l,
upon the striking of the elements.30 against any solid memher,
a sensor of pressure, force or the'like 102, ~hich is: particu-
larly r~sponsive -to pressure required to ].ower the' piston con-
tained within the cylinder 96 r and consequently responsive to
resistance to vertical downward move~ent that the element~ 30
may meet, ~i,ll be operative -to actuate'the valve 101, to cause
an upward movement t or retracti.on of the ass~embly 40, and con-
sequently of the eIements 30 carri.ed thereby, in order to preven-t
damage to the apparatus, or to b~tteries be~ng welded~
Also, ~ith reference to Fi.g. 1 r i-t ~ill be noted that
the rod 41 is pro~ided with a guide, comprising a pla-te 103
havlng a boss 104 disposed a~out the'rod 41, and carried by the
plate 103, and with a guide rod 109 bein~ provided, mounted in
a sui.table bushing 105 carried ~y a plate'106, such that, upon
downward movement of the rod 41, the'same is guided a~ainst
undesirable lateral movement, due to the presence of the ~uide
plate and rod 103'and 109~
It will thus ~e'seen that -the apparatus of this inven-
tion is adapted toward accomplishin~ its desired end~, both in
broad respects, and in specific respècts; regarding ~he con-
struction of multiple-ceIl lead~acid stora~e batteries.
It ~i11 further be'noted that the particular in~ardly
bent orientations of the nozzIe$ 81 and 82, present the appli-
cation of heat to ad~acent areas, thereby concentrating the heat
on the eIements 30 themselves~ It ~Jill also be noted that the
element 30 may be adjustable posi.tioned vertically within the
bli,nd hole 83 7 by merely loosening the scre~ 84 and reposi,tion-
ing the element 30. Furthe'rmore,' in operation, a proper pQSi~
tioning of the battery can actuate a switch (not shown~, that
in turn ~i:ll cause the piston within the c~linder 36 to be
actuatedl if desired.
In view of the a~ove~discussed invention, it has been
~1
~7
possible to cut down the time necessary for completi.ng a
weld rom thirty seconds to four seconds. Accordingly, aside
from accomplishing improved welds, both insofar as their physi-
cal appearance and construction is concerned, and insoar as
improving the uniformity and electrical conductivity of the
same is enabled, the overall economics of bat~ery manufacture
is greatly improved, due to the automation of what has previous-
ly been a manual functionO
An additional advantage over prior techniques of bat-
tery post weldment is also made possible ~^7ith weldments of this
invention. Such resides in the fo.rmation of a homogenous weld
ment of adjacent battery posts. Spectrographic analysis of
battery posts welded by conventional application of gas and
oxyyen flame directly to the post results in a tendency toward
concentration of antimony from the posts at or near the bond of
the weld, apparently caused by more severe heat at such locations
relative to less heat applied to other areas of khe ~eld. In
thermal relay welding as taught by the instant invention,
spectrographic analysis will reveal similar grain structures
throughout the weld, in that the entire post area is heated
uniformly and therefore cools evenly, without causing an anti-
mony precipitation th,at would result in an antimony concentration.
Consequently, the:possibility of eIectrolysis at the antimony
interface that forms the junction of dissimilar metals upon
use of the battery in an electxical circuit is avoided by this
invention, a~ong with any corrosion attendant thereto. Further-
more, the structural strength of the post weldment is better,
kecau~e of the absence of subs~antial discontinuities that
would. be formed by.such antimony precipi.tatioin.
The foregoing discussion has emphasized the structure
of the heating elements and the apparatus whereby combustible
~ ,~
~ 2~
gases are delivered for the he~t,ing thereof. Figs. 6 through 9
show an alternate illustrative embodiment wherein the heating
elements are integrated with the templates lowered over the
battery to form molds forthe foregoing heating and melting
process oE the terminal posts. Moreover, the embodimen-t of
Figs. 6 thorugh 9 features the heating elements and the molds
in an integral adjustable confiyuration such'that batteries
having widely disparate structural characterlstics may be
pxocessed efficiently ~rithout, requir~ng extensive overhaul of
the processing mechanism.
In the following description, many elements are iden-
tical both in structure and in function to corresponding ele
ments in the foregoing discussion. Many of these are numbered
similarly to the identical corresponding element, but further
including a prefixed ?17i~, Thus, for example, heating elements
730 in Figs~ 6 and 7 correspond identically to the heating
eIements 3~ in Figs. 1 through 5d. Unless otherwise specified,
these identical elements shall not be discussed in detail~ ~ut
shall be assumed to ~e disclo~ied completely in the foregoing.
In Fig. 6, a welding mechanism is set up for forming
two terminal posts for batteries~ Thus, while the foregoing
embodiment included six weIding mechanisms for cell to ceIl
relays in batteries, the embodiment of Figs. 6 through 9 is
configured only to form the positive and negative terminal
posts. It is to be understood, howe~er, that any desired num~
ber of heating elements might be included in order to fulfill
the desired welding re~uirement5 for given batteries. Likewiser
the embodiment of Figs. 6 through'g includes several features
which enhance the adaptability and therefore the utility of
,3~ thermal welding apparatus embodying the principles of the present
invention.
~3
In the figures, a pair of heating elements represented
generally as 752 are affixed to a pair of mountlng blocks 612
and 613, which in turn are slidably mounted on a transverse
rod 611. This transversely movable mounting permits lateral
adjustment of the heating elements 752 to accommodate batteries
having terminal posts located at different points. The trans-
verse rod 611 upon which the blocks 612 and 613 are mounted is
terminated at either end by a pair of elements 609 and 610.
Overlaying both of the mounting blocks 612 and 613 and a~fixed
to the elements 609 and 610 is a pla-te 623 whlch affords con-
trol of the adjustability function and whlch shall be described
in more detail hereinafter. Also mounted on the rod 611 is a
fixed block 930 which is in turn connected to the piston 830
of a pneumatic or hydraulic cylinder 630. Together, the blocks
609, 610, 612, 613 and 930, with the rod 611 and the plate 623r
form a "carriage" to which the heating elements 752 are attached,
by means of which the heating elements may be moved ~ertically
~such as shown in phantom in Fig. 7~ and upon which the respec-
tive heating elements may be adjusted transversely.
The terminating blocks 609 and 610 of the carriage
upon which the heating elements 752 are mounted are in turn
slidably mounted on posts 607 and ~08, respectively~ by means
of bearings, not shown. Thus, under the control of the cylin-
der 630 and piston 83Q, the carriage arrangement including the
heating elements 75~ is moved vertically on the posts 607 and
608 which are connected at their tops and bottoms, as shownl to
elements 616, 617 and 631. Topmost element 631 in turn is
mounted on posts 632 and 633, which con~titute part of a struc-
tural frame for the mechanism.
Also fixedly mounted on the posts 607 and 608 is a
2~
manifold head 743 which defined conduits 746 and 747 fed by
lines 601 and 6Q2 with a cQmbustible'gas for ~'lame heating o~
the heating elements 730.' As in the foregoing embodiments~ the
gases pass through the conduits 746 and 747, through hoses 761
and 762 and into mixing devices 757, and thence down~ardly into
the heating means 752. As shown~ only two sets of hose~ connect
the heating means752 with the manifold head 743, hut it is clear~
that any number, as desiredl might simil~rly be connected, A1$Q
mounted on the manifold heads 743 ~s the`cylinder 630 ~hereby
the mounting carriage for the'heating ~eans'752 is movable.
An aspect of the embodiment of Figs. 6 through 9
which exhi,bits substanti.al operational efficiency but w~ich
was not shown in detail in the foregoing embodiments i5 the
inclusion of a pair of molds 619 and 620 Which respectively are
connected to the mounting blacks 612 and 613 for -the heatin~
means 752, The molds 6I9 and 620 are slidably mounted on a
transverse post 618 through bearings: such as 818 and are res:pec-
tively mounted on shafts 626 and 627 which are slidably movable
through the blocks 612 and 613. It may therefore be seen that
the molds 619 and 620 are movable as a unit with the upper
mounting carriage for the heating ~eans 752 but furthermore are
separately movable together by means of the sliding of shafts.
626 and 627 through the: mounting bl'ocks 612 and 613.
The molds 619 and 620 are advantageously constructed
to provide superior operational efficiency~ which in turn ~s
enhanced by their adaptabili;ty to process batteries of variable
size. This may be appreciated by consideration of the var~ous
cutaway views of Figs. 7 and 8~ The principal s~tructural member
cf the ~olds 61~ includes. a hollo~ channeI 834 ~hich is fed and
exhausted by a pair of lines 63~ and ~34. The channel 834 pro~
0
vides a circulation route for water or other similar cooling
fluids to be passed through, and thereby to prevent damage due
to the extreme amounts of heat applied by the heating elements
730 to make the molten terminal postsO Centrally located on
the flat portion of the structural housing 619 is a mold member
621 which mates with the structural housing and which actually
form.s the voids in which the melting and casting process takes
place. The mold members 621 and 622 fit into a hole through the
structures 619 and 620 and are locked therein by means of a
slotted key 901 which locks the mold member 621 in place ~hen
situated as shown in Figs. 7 and 8,but which allows for removal
of member 621 when rotated 1~0 because the slot 905 then clears
the outer periphery of the membér 621. Lever arm 903 on the key
901 limits the rotary motlon of the key by cooperating with
extension members 902 and 904.
The mold members 621 and 622 are configured as shown
to define voids 721 having an upper portion which is coun~ersun]c.
Thus, when the heating member 730 is lowered as shown in phantom
in Fig. 7 to heat and melt the terminal posts as shown in F-~gs.
20 ~ l~a through lOd the level of the molten metal rises up into the
countersunk portion, but when the heating element 730 is removed~
the level settles back into the lower portion of the void 721 to
dry in the standard configuration of a terminal post. In accord-
ance with standardized procedures, positive and r.egative termin-
als of batteries are of different dimension in order to facili-
tate proper connection with external apparatus. In order to
accommodate the wishes of various customers, the mold members
621 and 622 may have different sized voids 721, and may be rear-
ranged between the molds Sl9 and 620 as desired. Moreover, the
molds 621 and 622 shown may be freeIy interchanged with other
similar member~ of different inner-configuration to process bat-
tery elements of varying size and configuration, as desired.
Fig. 9 shows a view of the overlYing plate 623 which
is affixed in the carriage assembly to end blocks 609 and 610 by
means of cam means 624 and 625l and which, when so situated,
determines the lateral position of the heating means 752. More
particularly, the securement means 624 and 625 fit through slots
906 and 911 in the plate 623 and screw or bolt into the termin-
ating blocks 609 and 610. The face of the plate defines first
and 5econd sets of openings 907 and 910, and a plurality of
sets of openings such as 908 and 909 extending across the face
of the plate. Once the securement members 624 and 625 mount the
plate onto the carriage assemhly, set screws such as 912 through
seIect ones of the end holes 907 and 910 establish the vertical
location of the plate 623A Thereupon~ a position is established
for the support blocks 612 and 613 because they are affixed to
the plate 623 by screws 628 and 629 through appropriate ones of
the holes 908 and 909. Thus, use of particular ones of the
holes 907 and 910 establish which of the holes 908 and 909 lor
any other such sets of holes, as desired) to which the blocks 612
613 shall be mounted. It is to be understood that by alteration
of the holes such as 908 and 909, any desired position of the
heating means 752 on the shaft 611 may be established. Since
the molding apparatus 619 and 620 is affixed to the respective
blocks by means of osts 626 and 627, similar positioning is
established for the molding apparatus 619 and 620 on the lower
shaft 618. Likewise, in order to accommodate different numbers
of heating means 752, it would only be re~uired to establish
correspondingly more sets of holes in the plate 623.
In a preferred mode of operation, the embodiment in
Figs. 6 through 9 operates as sho~ in Figs. 10a through 10d.
In Figs~ 10a through 10d, a bushin~ 920 i.s mounted around the
post hole of the battery casing 732 as is practiced in the art.
Thereupon, as the casing is assembled, a terminal post 921 fits
into the metallic bushing, to be welded thereto by application
of apparatus embodying the principles of the present invention.
In order to prepare the mach.inery of Figs. 6 thorugh 9 for
operation, the plate 623 first is adjusted as desired to locate
the heating means and the molding means appr¢priateIy over bat-
teries to be processed. Once a battery is positioned beneath
the Fig. 6 apparatus by means of a conveyor or the like, no-t
shownr the cylinder 630 and piston 830 are energized to lower
the carriage assembly and the molding apparatus downwardly onto
the battery as shown in Fig. 10a. The first portion to make
contact with the battery includes the molding means, ~hich seat
as appropriate over the portion to be processed as shown in Fig.
10b. Thereupon, however, the cylinder 630 and piston 830 con-
tinues to exert downward force upon the carriage assembly, as
shown in Fig. 10b, and a sliding of the carriage over the down-
ward shafts 607, 608, G26 and 627 res.ults, such as ~hown in
phantom in Fig. 7. Once the heating means 752 are lowerd to
the desired position, as shown in Fig. 10c, the meItin~ proce$s
of bushing 920 and post 921 as described hereinbefore is conduct-
ed, after which the heating means 752 first are withdrawn and
sufficient -time is allowed for the molten terminal post to set~
as shown in Fig. 10d, and the entire assembly is then ~ithdrawn
upwardly.
~ t may therefore be seen that the principles of the
present invention provide substantial flexibility, in that vari-
able numhers of heatin~ means 752 may be utilized~ but all are
freely adjustable in accordance with the established structure
, . . ~
``" ~l~Z~
of the plate 623, sy utili~ing associated molding mechanisms,
further adaptabili~y is provided since, first, unitary mold
mechanisms arc not needed, and secondly, the interchangeable
mold members 621 and 622 facilitate processes of different
types.
It will also be noted that, while the invention is
described and illustrated ahove~ it is principally for use with
multip'e-terminal applications, the same may be used for single
applications, regarding the welding oE batteries, and with
respect to other types of welding. The preferred embodiment
of the present invention is illustrated in a front elevational
view in Fig. 11. In Fig. 11 it may be seen that the automatic
post burn station of the present invention is primarily defined
by vertical support members 201 and 202 whi.ch are positioned
and supported by means of a transverse structural member 205
and by a bifurcated roller system including vertical supports 204
and 206. Batteries such as 218 pass along the roller system 203
for welding at the station, which weIding occurs in a position
under the welding assembly 213 as~ defined by stop roller 25~.
The assembly 213 includes a plurallty of burning tips matable
over the battery cover bushings of a battery such as 218. The
assembly 213 is vertically ~ovable by means of rods 214 and 216/
bearing assamblies 248 and 249, a pair of ccunterweigh:ts 306 and
307, and an air cylinder and piston assembly 241 and 245.
As may be clearly understood from Fig. 11, the mechan-
ism whereby a battery such as 218 is positioned for testing, and
whereby other batteries are precluded fro~ interferîng with the
testing process, is the use of up~ardly pivotable rollers from
the conveycr which therebyserve as stop mechanisms along the
conveyor~ Thus, under control of a cylinder 279 and a piston 281,
through connections of lever arms 278 and 299 and ti.e rod 280,
~q
rollers. 259 and 267 may be pi.v~ted upwardly and over their
next adjacent rollers, thereby forming a stop for batteries.
Whenever air pressure in the cylinder 279 is increased, the
piston 281 moves outwardly, along with tie rod 280 and rollers
259 and 267 again move downwardly to their normal positions~ The
batteries are then free to move down the conveyor.
Once a battery such as 218 is in abutment with the
pivoted roller 259, as shown, two fingers 286 and 287 are pivoted
upwardly and between the rollers, against the battery 218~ and
further until the battery 218 is locked into place in a predeter-
mined position with respect to a horizontal axis transverse to
the longitudinal a~is of advancement of the batteries. The up-
ward pivoting of fingers 286 and 287 occurs by means of yet
another cylinder and piston arrangement 283, energized ~y means
of appropriate control systems which will be more fully described
herein.
Whenever the battery 218 is positioned as shown in
~ig. 11, the welding assembly desi:gnated generally 213 will be
lowered into place. This occurs chiefly by means of the cylinder
241 and the piston 245 arrangement which is connected to a
shaft adaptor block 301 of the weIding assembly designated
generally 213. In order to ~acilitate this opera~ion~ the
welding assembly designated generally 213 includes up~ardl~
depending rods 214 and 216 which are connected, by means of lines
508 and 509, respectively, to a pair of counter~eights 306 and
307. These counterweigh.ts are located conveniently within the
upper portion of vertical support members 201 and 202. In pre-
ferred embodiments, the rods 214 and 216 pass through bearing
assembly 248 and 249, and the lines 508 and 509 pass over pulleys
located on cantilevered ~upport arms 219 and 221. sy means of
~a
. ~ _
~he counterweights 506 and 507, the ~ssembly designated generally
213 may also be kept in a nearly balanced condition/ such that
minimal force is necessary from the cylinder 241 and the piston
245 for either upward or down~ard movement. ~s seen in Fig. 11,
the weld ng assembly designated generally 213 is comprised of a
head means movable with respect to the frame of the apparatus
` along a vertical axis by means Oe the oper~tion of the cyl.inder
241 and rod 245 as described above~, and a mold means ad~ustably
mounted on said head means for slidably engaging said head means
along that vertical axis. The head means of the preferred
embodiment of the present inventîon comprises air cylinder 241,
cylinder rod 245, shaft adaptor block 301 r shaft manifold rods
303 and 305, respectively, manifold block 307, carriage blocks
309 and 311, respectively, and upwardly depending rads 214 and
216. The mold means, which i.s adjustably mounted in said head
means, is mounted on longitudinal supporting rod 313 extending
between carriage blocks 309 and 3Il. The mold carriage blocks
315 ~nd 317 act as the supporting structure for molds 319 and
321, which will be more fully described hereinafter. The appar-
atus shown in Fig. 11 illustrates the positi.on wherein the headmeans is in its molding position ~y means of the full extension
of rod 245, as indicated by the clearance of upwardly extending
rods 214 and 216 and the space di.sposed between shaft adaptor
block 301 and bearing assembli.es 248 and 249. Upon activation
of cylinder 241, which is a double-acting cylinder, the head
means may be moved from the molding position as shown in Fig. 1
to a standby position wherein sh.aft adaptor block 301 is substan-
tially contiguous to bearing assemblies 248 and 249. The burning
means of the present invention is capable o~ selectively ~roducing
a flame for melting the battery elements to be fused, said burn-
ing means keing mounted in slidable engagement along the vertical
3l
~ Z~
axis of movement of the head means, being slidably movable in
that axis ~ith respect to said head means. Hydraulic cylinder
323, which is a double-acting hydraulic cylinder, and rod 325,
which is associated therewith, are actuatable to produce the
movement of torch carriage 3Z7 along the lower p~rtions of
manifold shaEts 303 and 305. As may be seen in E'ig. 11 t locating
template 329, similar in function to the locating template des-
cribed above in other embodiments of the present invention, are
provided on the torch carria~e for precisely positioning the
burning tips 228 and 233 within the longitudinal axis of adva~ce-
ment of the batteries along conveyor 2Q3. As illustrated in
Fig. 11, the torch carriage 327 is in the front burning position,
as îndicated by the close proximit~ bet~een the burning tips 228
and 233 and the molds 219 and 32II respectiveIy. Movement to
the burning position has been pxoduced by the extension of rod
325 in response to the acti~ration cf hydrauIic cylinder 323~
Not shown in Fig. 11l but important to the functioning of th~ ;
~orch carriage in a safe manner, is tha pro~ision of spring
biased means extending bet-~leen the manifold hlock 307 and the
torch carriage designated generally 327, which spring biased
means act to return the toxch means to its pilot position in
the event of po~er failure. In normal operatlon, however, the
torch carriage is returned to its pilot position th~cugh acti-
vation of hydraulic cylinder 323, which causes th~ retraction
of rods 3~5 and consequantly draws torch carriage 327 towards
manifold block 307, so that the torch carriage and manifold
block are substantially contiguous to each other. In the burn--
ing position, as shown in Fig, 11, the trip bar 340 is shown
engaging and depressing trip levers 341 and 342, which are at-
tached to torches 343 and 344 respectively, and which trip levers
3~
. ~ _
act to control the intens,ity of the flame produced at burning
tips 228 and 233 respectiveIy. Oxygen and' combustible gas are
provided to torches 343 and 344 by means of gas supply line 345
and 346, which are ln communication with suitable sources of
oxygen and other combustible gases.
Referring now to Fig~ 12, wh~ch is a perspective view
of thè weIdin~ assembly designated generally 213 r the. operation
of the preferred embodiment of the present invention can best
be explained. As seen in Fig. 12, the torch carriage designated
generally 327 is in its pilot position, at which time the flames
emanating from burning tips 228 and 233 would be of the minimum
itensity~ Carriage blocks 3I5 and 3~7 are seen to be mounted
in sliding engagement alo~g a longitudinal axis on longitudinal
bar 313, ~hich is supported at either end by carriage hlocks
309 and 311. Torches 343 and 344 are mounted at an acute angle
with respect to the`vertical axes of radial symmetry of burning
tips 228 and 233 so that torch'levers. 341 and 342 are disposed
over trip bar 340. L bracket~.371 and 372'are fixedly attach.ed
to manifold shafts 303 and 3~5 respec~ ely by means of U bolts
373 and 374. Trip har 340 is he.ld in rotati.ng engagement be~
tween L brackets 371 and 372 by means of cotter pi.ns pi.ercing
said trip bar 340, which engagement allows trip bar 340 to
rotate upon engagement ~ith torch'levers 341. and 342. ~s $een
in Figs. 12 and 13, as the torch.caxriage designated generally
327 moves from its pilot position to the ~urning positlon ! as
shown in phantom in Fig. 13, the torch. 344 and torch lever 342
are brought down to engage the trip ~ar 340,. shbwn ~n cross
section in Fig. 13.' Since the' torch lever 342 is adapted to
control the intensity of the flame produced at the burning tip
233, it may be seen that as the torch carriage designated qen-
z~
erally 327 move5 in the di.recti.on of the: arro~r sh~wn in Fig~ 13from the pilot to the burning positionr the itensity of the flame
produced at the burning tip Z33 is correspondingly increased. As
may cl.early be seen in Fig. 13, the disposition of the hurning
tip 233 with res.pect to mold 32~ allows the flame produced at
burning tip 233 when the to`rch carriaye is near the pilot position
to preheat in a yentle manner the bushing and battery terminal
posts which would normally be disposed within the mold 320 when
the head means was in the molding position~ l'he mold carriage
block 317 which acts as a support for mold 320 is seen to h.ave
disposed therewithin at least one circulating chamber having
cooling fluid 397 disposed therei.n for cooling the mold carriage
block 317 during the molding process. Furthermore, the block
itself is selec-ted for its high. heat transfer capacity, and is
therefore composed of aluminum or other high.heat trans.fer mat-
erial. Similarly, and in di.rect opposition to the prior art
teaching ~ith respect to lead molds, the mold 32Q i5 itself
composed of aluminum or other high heat transfer materi.al. ~5
seen in Fig. 13, the enga~ement of mold 320 with mold carriage
2Q hlock 317 i5 tight, therefore allowing good heat transfer between
these elements and coolin~ fluid 3g7 which is constantl~ bein~
circulated therethrough. The interior surfaces 396, 395 and 39
ofi mold 320 have dlsposed thereon an aluminum oxide coating or,
that is, the interior surfaces 394, 355 and 396 are anodi~ed in
order to create a thermal ~arrier ~et~ee:n the mold void defined
by the mold 320 and the solid aluminum which composes the mold.
The remainder of the apparatus of the head means and
burning means may be seen in Fig~ 13 to compri~e vertical guide
rods 399 and 4Q0, which.transverséIy allgn the mold 32Q with
the ~urni.n~ tip 233 as that ~urning tip moves from the pilot to
3~
2~
the burning position. Longitudinal guide xod 393 for allowing
longitudinal adjustment of the posltion of the burniny tips with
respect to the longi-tudinal axis of the batteries is seen in cross
section in Fig. 13, as is a cut away portion of the torch carriage
designated generally 327 to reveal conduit 392 having a threaded
bushing 391 and 390 attached to tubing`398. Tubing 389 provides
a gaseous conduit Eor the mix-ture of oxygen and combustible gas
which is produced upon activatioll of the lever 342 within torch
344. Bushing means 388 are provided for interconnecting the
tubing 389 with the torch 344~ ~long the lower surface of the
torch carriage designated generally 327 and disposed between the
torch carriage 327 and the burning tip 233'is seen ta he a ~arrel
on which the burning tip may easily removably be mounted. The
gas supply conduit 346 is seen to ~e attached to the remote end
of tcrch 344, enter and are disposed ~ithin manifold block 307~
and are seen to emerge from manifold block 3Q7 in Fig. 12, from
whence they will be connected to suitable oxygen and combustible
gas sources.
Having described the apparatus Oc the preferred em~odi-
ment of the present invention/ the operation of that apparatusin fusing battery cover bushings to ~attery terminal posts may be
described as follows:
F.igure 14 is a schematic representation of the va~ious
sensing means of the preferred embodiment of the present invention
shown in association ~ith. a front ele~a-tion of an apparatus in
accordance ~ith the preferred embodiment of the invention similar
to that sho~n in Figure 11. Figure 14 shows and is intended to
highlight the automated features of the preferred embodiment
which, under normal operating conditions, will function entirely
without an operator being present~ The conveyor means in Figure
.~
291~0
14 is shown with the battery 218 in the fusing position. The
battery 218 is brought in -to the fusing position by its in-tro-
duction from the hold position, shown in phantom in Figure 1~ to
its operating position. Upon the longi,-tudinal advancement of
the battery 218 from the hold position to the operating position,
movable rollers are in the normal position, feed sensing means Sl
as shown in Figure 14 is activated by the passage of the battery
thereby. Consequently, the feed ~ensing means Sl is mounted on
the apparatus for sensing the longitudinal advancement of a
battery from the hold position towards the operating position,
and for causing the stop means to move from the normal position
which does not impede the longitudinal advancement of batteries
to the stop position wherein the batteries are held at the hold
and operating positions. The feed sensing means further causes
the delayed activation of clamp means comprising hydraulic cylln-
der 283 and fingers 286 and 287 which are pivoted upwardly and be-
tween the rollers against battery 218 and are further driven by
cylinder 283 until battery 218 is locked into place in a predeter-
mined position with respect to a horizontal axis transverse to the
longitudinal axis of' advancement of the batteries. In the pre-
ferred embodiment of the present invention the feed sensing
means is adapted to actlvate tha clamp means including cylinder
283 in a timed response interval which is between 0.2 and 5
seconds after the sensing of the passage of battery 218 from
the hold to the operating positi,on. This time delay interval is
selected to allow battery 218 to abut roller 259 prior to the
activation of the clamp me~ans. Aliynment sensing means S2 is
provided to sense the full extension of fingers 286 and 287
either directly, or indirectly as shown in Figure 14 by sensing
th~ degree of rotation of a protrusion mounted on a shaft which
rotation corresponds to the rotation of fingers 286 and 287.
Once the alignment sensing means S2 ~eter~,ines the full moveme~t
3,~
~"
~2f~
of the clamp means to the ~fully clamped posi:tion~ i,ndicating that
the battery has been forced ~rom the, operating tr~ the fus~ng
position, cylinder 241 is th~n activated to mave th.e head means,
which comprise~: the weIdlng assembly desïgnated generally 213
in the direction as indicated by arro~ A. Since the battery 218
is in precise alignment with.'res.pect to the weldin~ assembly 213,
the mold carriage blocks 315 and 3I7, and the` corresponding molds
contained therein will matabl~ encircle the battery bushing
elements and battery post eIements protruding rom the top o;E
battery 218. In the event that battery 2I8 has been remo~ed
from the apparatus or, in the'event that no battery has been
in-troduced into the apparatus due to machine malfunctIon, abort
means S7 will be activated by the'tra~eI of the weld~ng assembly,
and particularly, by the travel of rod 214 beyond the noxmal
molding position. Upon the act~vation of ah~rt mean~ S7 caused
by the absence of a battery in the fusing pos~tion, the remaining
portion of the operating cyc]e of the apparatus is the`n overxidden,
preventing the` actiVatiQn of the b.uxning or torch carriage ~nd
causing the im~ediate return o the hbad means and ~eIding as$em~
'oly to the standby position, and further cauSing the's-top mean$
to move from the stop to the. normal po$ition so that the'next
battery may be introduced into the apparatus. If a battery r 5uch
as battery 218 shown ln Piyure'14, is present when th.e welding
assembly designated generally 213 moves from the standby to the
molding position, ~attery sensin~ means S3 ~ill ~ense'the presence
of a battery in the fusing position and ~i11 thereb~ activate h,y-
draulic cylinder 323 to produce movement of the':torch.'carriage
327 along the lower portions of mani.fold shafts 303 and 305,
As hereinabove described, the burnin~ means m~unted Qn the torch
carriage comprises lever means for contacting a trip member
which automatically regulates the intcnsity of the flame from
a minimum pllot flame when the burning means is in the pilot
position to a maximum when the burning means is in the burn posi-
tion as shown in Figure 14. Consequently/ the battery sensing
means produces a movement of the torch carriage designated gen-
erally 327 in the direction as indicated by arrow B in Figure 14
to a point as shown in Figure 14 in the burning position wherein
a maximum flame intensity is directed at the battery bushing ele-
ment and battery post element encircled by each mold.
UPOI1 movement of the torch carriage designated generally
327 to its fully extended burning position, a travel sensing
means S4, which is mounted on the head means as shown in Figure
14 senses the presence of the burning means in that burning posi~
tion and causes the aforementioned hydraulic cylinder 323 to
immediately begin moving the burning means back to the pilot
position, as designated in Figure 14 by arrow C. ~he aforemen-
tioned trip member and lever means respond to this retraction by
reducing the intensity of the flame until, when the torch car-
riage reaches the pilot position, a return sensing means S5 which
is mounted on the torch carriage designated generally 327 deter-
mines the return of the burning means to the pilot position and
causes cylinder 241 to move the head means to the standby posi-
tion as indicated by arrow D in Figure 14 in timed response thereto.
In the preferred embodiment of the present invention, cylinder
241 is activated hy a delay interva~ of between 0.2 to 5 seconds,
which time period creates a post chill time following the return
of the torch carriage to the pilot position which is sufficient
to allow at least partial solidification of the battery terminal
posts. Activation of cylinder 241 to return the head means along
the direction of arrow D shown in Figure 14 causes the head means
to re-turn to the standby position. Reset sensing means S6 mounted
on the head means, or alternatively, on the transverse structural
3~
~2~
member 205 senses and determines the movement of said head
means to said standby position causing the stop means ~o move
-from the stop to the normal position, thereby allowing the
passage of the battery which terminals were fused out o~ the
fusing position while simultaneously allowing for the intro-
duction of the next battery to be processed into the operating
positioll as hereto~ore described. In order to facilitate this
longitudinal advancement of batteries, the clamp means is
similarly caused to move to the retracted positon by t~le reset
means S6 thereby causing ~ingers 286 and 287 to withdraw to
the retracted position, thereby also resetting alignment
sensing means S2.
As a result o-f the above description, it is apparent
that the apparatus o~ the present in~ention is -fully automated
facilitating the rapid and reliable production of batteries
incorporating high quality integrally fused battery terminals.
It will be understood that various changes in the
details, materials and arrangement o~ parts which have been
described and illustra~ed in order to explain the nature of
this invention, may be made by those skilled in the art within
the principle and scope of the invention as expressed in the
appended claims.
39
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