Internship Report

Muhammad Ahmed Shakeel

Abstract:
This internship report gives a thorough rundown of the encounters, discoveries, and learnings made
during an insightful internship in Exide Batteries. The main goal of this internship was to learn about
the inner workings of a contemporary battery production facility firsthand and to comprehend its
procedures, technologies, and environmental policies. The paper examines the plant's general design
and operation while highlighting the crucial responsibilities played by several departments throughout
the battery production process. The background of the company, its goals, and the importance of
batteries in the global energy landscape are explained in the report's opening paragraphs. The
infrastructure and layout of the facility are described in depth, with examples of the design features
that promote effective production procedures and guarantee worker safety. The internship
concentrated on a variety of aspects of the battery production process, such as the sourcing of
materials, the construction of battery cells, quality control techniques, and security standards. The use
of modern technology and automation in simplifying processes and improving product consistency is
given special consideration. Emphasis was made throughout the internship on the plant's dedication
to environmentally conscious business practices. The report details the steps taken by the battery
facility to minimize waste, lower energy use, and recycle materials, all of which help to promote a more
environmentally friendly future. In addition to the technical components, the report explores the
organizational structure, culture, and collaboration dynamics at the factory. To understand how
leadership and communication practices affect both overall productivity and employee satisfaction,
observations about these practices within the plant are analyzed.

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Table of Contents
Battery: ................................................................................................................................................... 3
Types of Batteries: .................................................................................................................................. 3
Lead Acid Batteries: ........................................................................................................................ 3
Flooded Lead-Acid Batteries: .......................................................................................................... 3
Batteries with valve regulation (VRLA):........................................................................................... 3
Lithium-Ion Batteries (Li-ion): ......................................................................................................... 4
Nickel-cadmium (Ni-Cd) Batteries: .................................................................................................. 4
Nickel-Metal Hydride Batteries (Ni-MH): ........................................................................................ 4
Lithium-Polymer Batteries (Li-Po): .................................................................................................. 4
Lead Acid Batteries Revised: .......................................................................................................... 4
Components of a Battery: ...................................................................................................................... 5
Manufacturing Process of Lead Acid Batteries: ..................................................................................... 6
Grid Production: ................................................................................................................................. 6
Oxide Mills: ......................................................................................................................................... 7
Mixers: ................................................................................................................................................ 9
Pasting: ............................................................................................................................................. 10
Curing: ............................................................................................................................................... 11
Formation: ........................................................................................................................................ 13
Drying: .............................................................................................................................................. 14
Plate Cutting: .................................................................................................................................... 16
Final Assembly: ................................................................................................................................. 16
Testing: .............................................................................................................................................. 18
Material Testing (LAB): ..................................................................................................................... 19
Conclusion: ........................................................................................................................................... 20

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Literature Review:
Battery:
Batteries are devices that store energy and use electrochemical reactions to transform chemical energy
into electrical energy. They are portable power sources that are widely utilised for a variety of
purposes, from supplying energy storage for electric cars and renewable energy systems to small
electronic devices like laptops and cell phones.

In order to improve the overall voltage and capacity of the battery, one or more electrochemical cells
are often linked in series or parallel. Each cell is made up of an anode and a cathode that are submerged
in an electrolyte solution that serves as a medium for the transfer of ions during chemical reactions.

Electrons move from the anode to the cathode through an external circuit during the discharge
process, producing an electric current. The electrodes and electrolyte alter chemically as a result of
this process, which sets off a chemical reaction in the cell. When a battery is recharged, the chemical
reactions and the direction of the current are reversed, restoring the battery's ability to store energy.

Lead-acid batteries, lithium-ion batteries, nickel-cadmium batteries, and more battery types exist, each
having a distinct chemistry and set of properties. Because of improvements in energy density,
longevity, and efficiency brought about by battery technology, batteries are now crucial parts of
contemporary electronic products and the shift to cleaner energy sources.

Types of Batteries:
There are various battery types, each with a unique chemical and set of properties. The following are
some popular battery types:

Lead Acid Batteries:

One of the oldest and most popular forms of rechargeable batteries are lead-acid batteries. They are
well recognised for being reasonably priced, durable, and able to supply a large burst of current, which
makes them appropriate for a variety of applications. These batteries are made up of sulfuric acid
(H2SO4) electrolyte and lead (Pb) electrodes.

Flooded Lead-Acid Batteries:

In this conventional design, the electrolyte is in the form of a liquid, and the battery must be
held upright to prevent leakage. Water levels must be checked and replenished on a regular
basis.

Batteries with valve regulation (VRLA):

VRLA batteries, also referred to as sealed lead-acid batteries, are created to require minimal
maintenance. They eliminate the need to add water on a regular basis by using a one-way
pressure relief valve to manage gas release and recombine hydrogen and oxygen into water.
The two types of VRLA batteries are further separated into:

1) Absorbent glass mat (AGM) batteries offer outstanding electrical performance and a high
level of vibration tolerance. AGM batteries store the electrolyte in a fibreglass mat.

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 2) Gel batteries employ an electrolyte that resembles gel to lower the possibility of acid
leakage and improve deep-cycle performance.

Lithium-Ion Batteries (Li-ion):

Lithium-ion batteries have gained popularity recently because of its high energy density, light weight,
and capacity to power a variety of devices, including electric vehicles and smartphones. They use a
lithium salt electrolyte with lithium compounds in the electrodes, such as lithium cobalt oxide, lithium
iron phosphate, or lithium nickel manganese cobalt oxide.

Nickel-cadmium (Ni-Cd) Batteries:

Because of cadmium-related environmental problems, nickel-cadmium batteries are now less
widespread than they formerly were. These batteries have an alkaline potassium hydroxide electrolyte
and metallic cadmium and nickel oxide hydroxide electrodes.

Nickel-Metal Hydride Batteries (Ni-MH):

Compared to Ni-Cd batteries, nickel-metal hydride batteries are said to be more environmentally
benign. They substitute the cadmium in the negative electrode with a hydrogen-absorbing alloy, and
the nickel oxyhydroxide in the positive electrode with an alkaline electrolyte.

Lithium-Polymer Batteries (Li-Po):

These batteries are a subset of lithium-ion batteries that utilise a polymer electrolyte rather than a
liquid electrolyte. They are frequently utilised when circumstances where thin form factors and
flexibility are necessary.

Lead Acid Batteries Revised:

Lead-acid batteries have been a workhorse of energy storage for over a century, finding applications
in automotive starting batteries, uninterruptible power supply (UPS) systems, backup power sources,
and renewable energy storage. Their popularity can be attributed to several factors:

1. Cost-Effectiveness: Lead-acid batteries are relatively inexpensive compared to other battery

technologies, making them a cost-effective choice for many applications.

2. High Starting Power: Lead-acid batteries can provide a high surge of current, making them
ideal for automotive starting applications.

3. Recyclability: Lead-acid batteries are highly recyclable, with a well-established recycling

infrastructure that helps recover and reuse materials, reducing environmental impact.

4. Established Technology: The technology behind lead-acid batteries is mature and well-
understood, ensuring their reliability and safety in various applications.

However, lead-acid batteries also have some limitations, such as lower energy density compared to
newer technologies like lithium-ion batteries, shorter cycle life in deep-cycle applications, and the need
for periodic maintenance in flooded lead-acid batteries. As a result, they may not be the optimal choice
for certain modern applications where higher energy density and longer lifespan are critical factors.
Nevertheless, ongoing research and advancements continue to improve lead-acid battery technology
and expand its potential applications.

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Components of a Battery:
A lead-acid battery is composed of several key components that work together to store and deliver
electrical energy. These components include:

1. Positive Plate (Cathode): The positive plate is made of lead dioxide (PbO2) and is coated onto
a grid structure. Lead dioxide is a compound that can accept and release oxygen during the
charging and discharging process.

2. Negative Plate (Anode): The negative plate is typically made of sponge lead (Pb) or lead-
calcium alloy. This material can react with sulfuric acid to form lead sulfate during the
discharge process.

3. Separator: The separator is a porous material placed between the positive and negative plates
to prevent direct electrical contact while allowing the flow of ions between them. The
separator ensures that the plates do not touch and cause a short circuit.

4. Electrolyte: The electrolyte is a dilute solution of sulfuric acid (H2SO4) mixed with water. It
provides the medium through which ions flow between the positive and negative plates during
the electrochemical reactions, enabling the battery to store and release electrical energy.

5. Cell Container: The cell container is usually made of a durable, acid-resistant plastic material.
It holds the positive and negative plates, separator, and electrolyte. The container is designed
to prevent leakage and protect the internal components from external elements.

6. Cell Covers: The cell covers seal the battery and provide access for adding water to maintain
the electrolyte level in flooded lead-acid batteries. In valve-regulated lead-acid (VRLA)
batteries, the covers incorporate pressure relief valves to control gas buildup.

7. Terminal Posts: Terminal posts are metal posts on top of the battery that allow electrical
connections to be made with external devices or circuits. They provide the points through
which the battery delivers its electrical output or receives charging current.

8. Plate Supports: Plate supports are structures within the battery that hold the positive and
negative plates in place, maintaining proper alignment and preventing movement that could
cause short circuits.

9. Gas Vent: In flooded lead-acid batteries, a gas vent is provided to release any gases generated
during charging. This vent prevents the buildup of pressure within the battery and helps
prevent explosions.

10. Electrolyte Level Indicator: Flooded lead-acid batteries have an electrolyte level indicator,
usually in the form of transparent windows on the cell covers. This allows users to monitor and
maintain the proper electrolyte levels.

In flooded lead-acid batteries, the electrochemical reactions between the lead dioxide and lead plates,
along with the sulfuric acid electrolyte, result in the conversion of chemical energy to electrical energy
during discharge and the reverse process during charging. In VRLA batteries, the design is modified to
recombine gases produced during charging, eliminating the need for adding water and allowing the
battery to be sealed. These components collectively enable the lead-acid battery to store and release
electrical energy efficiently.

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 Battery Type Composition Shelf Life

Conventional Lead Acid Battery Lead + Antimony (2.8%) 1 year

Maintenance free Battery Lead + Calcium (2-3%) 6 months

Manufacturing Process of Lead Acid Batteries:

The manufacturing process of lead-acid batteries involves several steps, each contributing to the
creation of functional and reliable batteries. Below is a detailed step-by-step explanation of the
process:

Grid Production:
Grid production is a crucial step in the manufacturing of lead-acid batteries. The grids serve as the
structural backbone of the battery plates, providing support for the active material that will undergo
chemical reactions during charging and discharging cycles. Here's a detailed explanation of the grid
production process:

1. Lead-Alloy Preparation:

• The process begins with lead-alloy preparation. Lead is typically alloyed with small
amounts of other metals like antimony, calcium, tin, or selenium to improve specific
properties of the grid, such as strength, corrosion resistance, and electrical
conductivity.

2. Melting:

• The lead-alloy ingots are melted in large furnaces at controlled temperatures. The
molten alloy is carefully monitored to ensure the correct composition and
temperature for casting.

3. Casting:

• The molten lead-alloy is poured into a casting machine. This machine uses a mold to
shape the alloy into long, flat strips that will eventually become the grid pattern.

• Cooling mechanisms within the casting machine solidify the molten lead-alloy,
forming thin strips.

4. Rolling and Cutting:

• The solidified strips are then fed into rolling mills. These rolling mills reduce the
thickness of the strips to the desired level while also enhancing their uniformity and
flatness.

• The rolled strips are cut into smaller sections, each of which will be used to create
individual grids.

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 5. Stamping:

• The cut sections of rolled strips are further processed through stamping machines.
These machines use precision dies to shape the lead-alloy strips into grid patterns.

• The grid patterns are designed to accommodate the placement of active material and
provide channels for the flow of electrolyte.

6. Alignment and Inspection:

• The stamped grids undergo alignment and inspection processes to ensure that they
meet quality standards in terms of dimensions, alignment of grid lines, and absence
of defects.

7. Final Inspection:

• Once the grids are prepared, they undergo a final inspection to ensure they meet the
required specifications and quality standards. Any grids that do not meet the criteria
are discarded.

The grids produced through this process are essential components of lead-acid batteries. They provide
a rigid structure for the active material, which is applied during the pasting step. The grids also serve
as conductive pathways for the flow of electrical current during battery operation. The quality of the
grids directly influences the overall performance and durability of the lead-acid battery.

Oxide Mills:
Oxide mills play a crucial role in the lead-acid battery manufacturing process by facilitating the
production of lead oxide, which is a key component of the battery's active material. Lead oxide is
used in both positive and negative plates of the battery, and it is produced through a controlled
process in oxide mills. Here's an explanation of the oxide mill process:

1. Purpose of Oxide Mills:

• Oxide mills are used to convert lead ingots or other lead sources into lead oxide. Lead oxide
serves as the starting material for creating the active material paste used in battery plates.

2. Types of Lead Oxide:

• Lead oxide comes in different forms, each with specific properties that suit various battery
applications. The primary types are litharge (PbO) and red lead (Pb3O4).

3. Oxide Production Process:

• The oxide production process typically involves two stages: oxidation and milling.

4. Oxidation Stage:

• Lead ingots are heated in a controlled environment to a specific temperature. The heat
causes the lead to oxidize, forming lead oxide particles.

• The oxidation process can be carried out using various methods, such as the Barton-Pot
process or the Ball Mill process.

5. Barton-Pot Process:

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 • In the Barton-Pot process, leady oxide is produced by tumbling lead balls inside a rotating
barrel. Air is blown through the system to accelerate oxidation.

• The lead balls gradually become coated with lead oxide particles, which are then collected
and processed further.

6. Ball Mill Process:

• In the Ball Mill process, lead oxide is created by tumbling lead balls in a rotating drum. The
friction and impact generated by the tumbling balls aid in the oxidation process.

• The lead oxide particles are collected as they are formed and are subsequently processed to
achieve the desired particle size and quality.

7. Milling Stage:

• The lead oxide particles obtained from the oxidation process are further processed in the
oxide mill to achieve the desired particle size distribution and consistency.

• Milling involves reducing the particle size of the lead oxide and ensuring that it is uniformly
mixed.

8. Importance of Particle Size:

• The particle size of lead oxide influences the characteristics of the active material paste and,
subsequently, the battery's performance.

• Smaller particles provide a larger surface area for the chemical reactions that occur during
battery operation.

9. Quality Control:

• Oxide mills include quality control measures to ensure that the produced lead oxide meets
specifications. Particle size, density, and chemical composition are among the parameters
monitored.

10. Active Material Paste Preparation:

• The lead oxide obtained from the oxide mills is a crucial ingredient in the active material
paste. This paste is used to coat the grids in the pasting process, forming the plates of the
battery.

In summary, oxide mills are essential for converting lead sources into lead oxide, which is a
fundamental component of lead-acid battery plates. The oxidation and milling processes in these
mills ensure that the lead oxide particles have the desired properties for creating high-quality active
material paste, leading to batteries with optimal performance and longevity.

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Mixers:
Mixing chambers play a pivotal role in the paste-making process of lead-acid battery manufacturing.
These chambers are designed to thoroughly combine the active material, water, and various
additives to create a homogenous paste. The paste is a critical component that coats the battery
grids to form the positive and negative plates. Here's an explanation of the mixing chamber's role in
the paste-making process:

1. Purpose of Mixing Chambers:

• Mixing chambers are specifically designed environments where the active material, water,
and additives are blended to create the paste that will coat the battery grids.

2. Active Material and Additives:

• Active material, typically lead oxide, is the primary ingredient in the paste. Depending on the
type of plate being produced (positive or negative), specific additives are incorporated to
optimize the paste's characteristics.

3. Water Addition:

• Water is a crucial component used to create a slurry with the active material. The slurry
facilitates the even distribution of the active material particles and other additives.

4. Thorough Homogenization:

• The mixing chamber's design and mixing mechanism ensure that all components are
thoroughly blended to create a homogenous paste. This is crucial for consistent battery
performance.

5. Mixing Mechanism:

• Mixing chambers employ various mechanisms to achieve thorough blending. These

mechanisms can include rotating blades, agitators, or other stirring devices.

6. Controlled Environment:

• The mixing process is carried out in a controlled environment to maintain consistent

conditions, such as temperature and humidity, which can affect paste quality.

7. Process Parameters:

• Various parameters are carefully controlled during mixing, such as mixing speed, duration,
and order of ingredient addition.

8. Quality Control:

• Quality control measures are implemented to ensure the paste's characteristics meet
specifications. Parameters like paste density, viscosity, and particle distribution are
monitored.

9. Paste Consistency:

• Achieving the right consistency of the paste is essential. The paste should be uniform, free of
lumps, and have the appropriate viscosity to facilitate its application to the battery grids.

10. Paste Application:

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 • The paste created in the mixing chamber is subsequently applied to the battery grids through
the pasting process. It forms a coating on the grids that becomes the active material of the
battery plates.

11. Process Automation:

• In modern battery manufacturing, some mixing chambers are equipped with automation and
monitoring systems to ensure precise control of process parameters and data collection for
quality assurance.

In summary, mixing chambers are integral components of the paste-making process in lead-acid
battery manufacturing. These chambers facilitate the careful blending of active material, water, and
additives to create a uniform and consistent paste. The quality of the paste produced in the mixing
chamber directly impacts the performance, capacity, and longevity of the resulting lead-acid
batteries.

Pasting:
Preparation of Active Material:

• Lead dioxide (PbO2) and sponge lead (for negative plates) are the primary active materials.
These materials are finely ground to create a powder with a high surface area, which enhances
their reactivity.

• Water is added to the active material powder to create a slurry. This slurry serves as the base
for the paste and allows for even distribution of the active material on the grids.

• Various additives, such as binders, conductive agents, and stabilizers, are mixed into the slurry
to improve paste adhesion, conductivity, and overall plate performance.

2. Coating the Grids:

• The pasting machine consists of a reservoir that holds the active material paste. The paste is
formulated to have the right viscosity for easy application.

• The grid structures, usually made of lead-alloy strips, are fed into the machine. The machine
has rollers that evenly coat both sides of the grid with the active material paste.

• The rollers' pressure and speed are controlled to ensure uniform coating and prevent excessive
paste application.

3. Formation of Paste Layer:

• Once the grids are coated with the paste, they are carefully stacked in racks. These racks hold
the grids in a position that allows the paste to settle and adhere to the grid surface.

• During this time, a natural process of diffusion and settling occurs, ensuring the paste fills the
grid's openings and covers the surface uniformly.

4. Curing:

• The racks of pasted grids are placed into curing ovens. The ovens are set at specific
temperatures that promote curing without damaging the active material or grid.

• The curing process serves several purposes:

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 • It evaporates excess water from the paste, leaving behind a solid, adherent layer of
active material.

• It enhances the bond between the active material and the grid, improving electrical
conductivity and durability.

• It stabilizes the paste structure, preventing shedding or flaking during subsequent

processing and battery operation.

5. Quality Control:

• Each pasted plate undergoes rigorous quality control checks. These checks may include visual
inspections, measurements of paste thickness and weight, and tests for paste adhesion.

• Plates that do not meet the required specifications are rejected to maintain consistent plate
quality.

Throughout the pasting process, precise control of factors like paste viscosity, roller pressure, curing
temperature, and drying time is crucial to ensure uniform paste application, strong adhesion, and
reliable battery performance. The pasting step sets the foundation for the electrochemical reactions
that take place within the battery, ultimately determining its capacity, efficiency, and overall lifespan.

Curing:
Curing is a crucial step in the manufacturing of lead-acid batteries, particularly during the pasting
process. It involves subjecting the pasted grids to controlled temperatures in curing ovens. This process
serves to solidify the active material paste on the grids, enhance its adhesion to the grid structure, and
improve its electrical conductivity. Here's a detailed explanation of the curing process:

1. Pasted Grids Preparation:

• Pasted grids, which have been coated with active material paste, are carefully arranged in racks
or trays. These racks hold multiple grids and ensure proper spacing between them to allow for
even curing.

2. Loading into Curing Ovens:

• The racks with the pasted grids are loaded into curing ovens. These ovens are specifically
designed to provide controlled temperature conditions that facilitate the curing process
without damaging the grids or the active material.

3. Temperature Control:

• The curing ovens are set at specific temperatures that are determined based on the type of
active material, the composition of the paste, and the desired properties of the cured paste
layer.

• The temperatures are generally below the melting point of the active material and other
components, ensuring that the curing process solidifies the paste without causing
deformation.

4. Evaporation of Solvents:

• One of the primary objectives of the curing process is to remove any remaining water or
solvents from the paste.

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 • The elevated temperature causes the water or solvents within the paste to evaporate. This
evaporation process results in the solidification of the paste, leaving behind a dense and
coherent layer of active material.

5. Formation of Chemical Bonds:

• The elevated temperature during curing promotes the formation of chemical bonds between
the active material and the grid structure.

• These bonds enhance the adhesion of the active material to the grid, preventing detachment
or shedding during subsequent battery manufacturing steps and battery operation.

6. Improvement of Conductivity:

• Curing contributes to the improved conductivity of the active material. The elevated
temperature allows for better integration of the conductive additives within the paste, creating
efficient pathways for the flow of electrical current during battery operation.

7. Duration of Curing:

• The duration of curing varies based on factors such as the type of active material, the thickness
of the paste layer, and the specific curing temperature.

• Curing times typically range from several hours to a day or more, depending on the specific
battery design and paste composition.

8. Cooling and Removal:

• After the curing process is complete, the ovens are turned off, and the temperature inside
gradually decreases.

• Once the temperature is sufficiently lowered, the racks containing the cured pasted grids are
removed from the ovens and allowed to cool before further processing.

Curing is a delicate and critical step that significantly impacts the quality and performance of the lead-
acid battery. Proper curing ensures the solidification of the active material paste, which is essential for
maintaining stable performance, preventing shedding or flaking of the paste, and enabling efficient
electrochemical reactions within the battery during charging and discharging cycles.

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Formation:
Formation is a critical step in the manufacturing of lead-acid batteries, particularly in creating optimal
performance and capacity. This process involves the initial charging and discharging cycles that
condition the battery plates and electrolyte. Formation helps establish the electrochemical reactions
required for efficient battery operation. Here's a detailed explanation of the formation process:

1. Preparation of Cells:

• Cells, each containing positive and negative plates immersed in electrolyte, are prepared for
the formation process. These cells are arranged according to the battery's design.

2. Initial Charging (Formation Charge):

• The formation process begins with the initial charging phase. A controlled electrical current is
applied to the cells.

• During charging, lead dioxide on the positive plates and sponge lead on the negative plates
undergo chemical transformations. The active material's structure changes to accommodate
the reactions that occur during battery operation.

3. Electrochemical Reactions:

• In the positive plates, lead dioxide undergoes conversion to a higher state of oxidation, storing
electrical energy in a form that can be released during discharge.

• In the negative plates, sponge lead is transformed into lead sulfate, which can release energy
during discharge.

4. Controlled Voltage and Current:

• The charging process is carefully controlled, with both voltage and current maintained within
specified limits.

• The voltage and current levels are chosen to avoid excessive heat generation or other
conditions that could lead to damage.

5. Discharge and Rest Intervals:

• After a specific charging period, the cells are discharged. This discharging phase is followed by
a rest period.

• The rest period allows the battery's internal components to adjust and stabilize. It also allows
any gases generated during charging to dissipate.

6. Repeated Cycles:

• The formation process typically involves multiple cycles of charging, discharging, and resting.

• Each cycle further conditions the battery plates, helping to optimize the electrochemical
reactions and stabilize the capacity and performance of the battery.

7. Monitoring and Control:

• Throughout the formation process, the cells are closely monitored. Measurements of voltage,
current, and temperature are taken to ensure that the process is proceeding as intended.

• Any deviations from the desired parameters can indicate issues that need to be addressed.

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8. Final Formation:

• The number of cycles in the formation process depends on the battery's design and intended
use. Some batteries may undergo a few cycles, while others might require more extensive
formation.

• The final formation process establishes the battery's basic performance characteristics, such
as capacity and cycle life.

9. Impact on Battery Performance:

• Proper formation enhances the battery's ability to store and deliver energy efficiently. It
ensures that the active material is appropriately conditioned and ready to undergo the
chemical reactions necessary for charging and discharging cycles.

Formation is a critical step that prepares lead-acid batteries for their intended use. It helps stabilize
performance, reduces capacity variation between batteries, and ensures that the battery can meet its
specifications over its operational life. The success of the formation process significantly impacts the
battery's overall quality, performance, and longevity.

Drying:
After the formation process in lead-acid battery manufacturing, the tunnel dry oven and inert dry oven
processes are often used to further optimize the battery's performance, stability, and safety. These
processes involve controlled heating and drying to remove residual moisture and gases from the
battery's components. Let's delve into each process:

Tunnel Dry Oven Process:

1. Purpose:

• The tunnel dry oven process is used to reduce the moisture content within the
battery's components, particularly the active material paste, separators, and other
materials that might have absorbed moisture during the formation process.

2. Process Overview:

• In the tunnel dry oven process, the batteries are conveyed through a controlled-
temperature tunnel oven on a conveyor belt system.

• The oven provides a controlled environment where the batteries are exposed to
elevated temperatures, usually below the temperatures used during the formation
process.

3. Drying Mechanism:

• The elevated temperature within the oven accelerates the evaporation of any
remaining moisture within the battery's components.

• The process helps ensure that the active material paste is sufficiently dried and the
battery's internal components are prepared for long-term stability.

4. Moisture Removal:

• As the batteries pass through the oven, the moisture within the components is
evaporated and carried away as water vapor.

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 5. Controlled Conditions:

• The tunnel dry oven process is carefully controlled to prevent overheating or damage
to the battery's components. The temperature and conveyor speed are adjusted to
optimize the drying without causing harm.

Inert Dry Oven Process:

1. Purpose:

• The inert dry oven process is designed to remove any residual gases within the battery
after the formation process.

• These gases can include traces of hydrogen and oxygen that may have been generated
during formation or charging.

2. Process Overview:

• In the inert dry oven process, the batteries are placed within a specialized oven or
chamber.

• The environment within the oven is purged with an inert gas, such as nitrogen or
argon, to create an atmosphere that prevents the recombination of gases.

3. Gas Removal:

• The presence of the inert gas prevents the recombination of gases, ensuring that any
remaining hydrogen and oxygen gases are carried away from the battery's internal
components.

4. Enhanced Safety:

• This process significantly reduces the risk of gas buildup within the battery, minimizing
the potential for explosive conditions.

Both the tunnel dry oven and inert dry oven processes contribute to enhancing the battery's
performance, safety, and long-term stability. By removing moisture and residual gases, these processes
optimize the battery's internal environment for efficient electrochemical reactions, reduce the
potential for self-discharge, and improve the overall consistency and reliability of the lead-acid
batteries. Proper implementation of these processes is crucial to ensure that the batteries meet quality
and safety standards.

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Plate Cutting:
• The stacked grids are transferred to a cutting station, where they are cut into individual plates.

• Cutting tools or dies are used to cut through the grid and the adherent paste layer to create
individual plates of desired dimensions.

• The cutting process requires precision to ensure that the plates are cut accurately and maintain
uniform dimensions

Plate Counting:

• After the plates are cut and potentially shaped, they are carefully counted to ensure that the
correct number of positive and negative plates are available for cell assembly.

• Plate counting is a critical quality control step to prevent errors in the assembly process and
ensure that each battery has the intended configuration.

Final Assembly:
The final battery assembly process is the culmination of various manufacturing steps and involves
putting together all the components to create a functional lead-acid battery. This process includes the
assembly of individual cells, interconnections, terminal fittings, and the necessary testing and quality
control checks to ensure the battery's performance and safety. Here's a detailed explanation of the
final battery assembly process:

1. Cell Group Assembly:

• The core of a lead-acid battery is the cell group, which comprises a specific arrangement of
positive and negative plates along with separators.

• Positive and negative plates are interleaved with separator materials to prevent short circuits
while allowing ion flow between plates.

• Depending on the battery's voltage and capacity requirements, multiple cell groups may be
assembled in series or parallel configurations.

2. Cell Container Preparation:

• Cell containers are usually made of durable plastic or other acid-resistant materials.

• The containers are designed to house the cell groups, providing protection and ensuring that
the electrolyte remains contained.

3. Electrode Stack Insertion:

• The assembled cell groups, along with separator materials, are placed into the cell containers.

• The arrangement of cell groups is based on the battery's desired voltage and capacity
specifications.

4. Electrolyte Filling (Flooded Batteries):

• For flooded lead-acid batteries, the cell containers are filled with the sulfuric acid electrolyte.
The proper amount of electrolyte is added to each cell.

• The electrolyte fills the space between the plates and allows for the necessary chemical
reactions to take place during battery operation.

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5. Terminal Fitting:

• Terminal posts, which provide connection points for external electrical circuits, are attached
to the battery.

• The terminal posts are securely fastened to the battery's cell containers, ensuring reliable
electrical connections.

6. Sealing (VRLA Batteries):

• In Valve-Regulated Lead-Acid (VRLA) batteries, the cell containers are sealed to prevent gas
escape and electrolyte leakage.

• Pressure relief valves are often integrated into the battery's design to maintain safe internal
pressure levels.

7. Quality Control and Testing:

• The assembled batteries undergo a series of quality control tests to ensure they meet
performance and safety standards.

• Capacity tests, high-rate discharge tests, voltage measurements, and other checks are
performed to validate the battery's performance.

8. Labeling and Identification:

• Each battery is labeled with essential information such as voltage, capacity, manufacturer
details, and safety warnings.

• Labels help users identify the battery's specifications and proper usage.

9. Packaging:

• The batteries are carefully packaged to protect them during transportation and storage.

• Packaging materials provide cushioning and insulation against potential impacts and
environmental conditions.

10. Distribution:

• The fully assembled and packaged batteries are then ready for distribution to various markets
and applications, including automotive, industrial, and renewable energy sectors.

The final battery assembly process involves meticulous attention to detail, quality control checks, and
adherence to safety protocols. By ensuring that all components are assembled accurately and reliably,
manufacturers can produce lead-acid batteries that deliver consistent performance and durability
throughout their operational life.

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Testing:
The testing process for lead-acid batteries is a crucial step in the manufacturing and quality control
process to ensure that the batteries meet performance, safety, and reliability standards. Various tests
are conducted to assess the battery's capacity, voltage, discharge characteristics, internal resistance,
and overall behavior under different conditions. Here's an explanation of the testing process for lead-
acid batteries:

1. Capacity Test:

• Capacity testing evaluates the battery's ability to store and deliver energy. It involves charging
the battery to full capacity and then discharging it at a controlled rate until it reaches a
specified endpoint voltage.

• The amount of energy (ampere-hours) delivered during the discharge cycle is measured and
compared to the battery's rated capacity to ensure it meets expectations.

2. High-Rate Discharge Test:

• High-rate discharge testing evaluates the battery's performance under high-demand

scenarios. The battery is discharged at a higher rate than usual to simulate conditions like
engine cranking in automotive applications.

• This test helps determine whether the battery can deliver sufficient current for applications
with rapid energy demands.

3. Open-Circuit Voltage Test:

• The open-circuit voltage of the battery is measured when it is not connected to any load or
charging source. This voltage provides an indication of the battery's state of charge.

• The open-circuit voltage can help diagnose the battery's condition and predict its capacity.

4. Internal Resistance Test:

• Internal resistance affects the battery's ability to deliver current effectively. This test measures
the resistance within the battery when a current is applied.

• Lower internal resistance indicates better efficiency and performance.

5. Cycle Life Testing:

• Cycle life testing involves subjecting the battery to repeated charge and discharge cycles to
assess its longevity and capacity retention over time.

• This test provides insight into how well the battery maintains its performance throughout its
operational life.

6. Temperature Testing:

• Batteries are tested at various temperature levels to evaluate their performance and behavior
under different environmental conditions.

• Extreme temperature testing helps identify how the battery responds to hot and cold
temperatures.

7. Overcharge and Overdischarge Testing:

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 • Batteries are intentionally subjected to overcharge and overdischarge conditions to evaluate
their behavior and safety under extreme stress.

• These tests assess the battery's ability to withstand potential abuse scenarios.

8. Short-Circuit Test:

• Short-circuit testing evaluates the battery's safety by intentionally creating a short circuit
across its terminals.

• This test assesses how the battery handles high currents and potential safety hazards.

9. Voltage and Current Measurements:

• Throughout various tests, voltage and current measurements are continuously monitored to
assess the battery's behavior and performance.

10. Quality Control Checks:

• Quality control tests include visual inspections to ensure proper assembly, labeling, and
packaging of the batteries.

Material Testing (LAB):

The laboratory testing of raw materials and in-operation materials in lead-acid battery manufacturing
is a vital quality control practice. It involves evaluating the quality, composition, and performance
characteristics of the materials used in the battery's construction and those generated during battery
operation. Here's an explanation of the laboratory testing process for both raw materials and in-
operation materials:

Raw Material Testing:

1. Lead Alloy Analysis:

• Incoming lead-alloy ingots are tested to ensure they meet the required composition
specifications. Analysis includes determining the proportions of various alloying
elements like antimony, calcium, tin, and selenium.

2. Active Material Analysis:

• The raw materials used in the active material paste, such as lead oxide for positive
plates and sponge lead for negative plates, are tested for purity, particle size
distribution, and chemical composition.

3. Electrolyte Analysis:

• The sulfuric acid used in the electrolyte is analyzed for its concentration, acidity, and
potential contaminants. Ensuring the correct electrolyte composition is essential for
proper battery performance.

4. Separator Testing:

• Separators, which prevent electrical contact between positive and negative plates, are
tested for parameters like thickness, porosity, and permeability. These properties
affect the battery's efficiency.

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Conclusion:
In conclusion, my internship experience at the Exide battery manufacturing plant has provided me
with valuable insights into the intricate processes involved in producing reliable and efficient batteries.
Through hands-on involvement and observation, I have gained a comprehensive understanding of the
various stages that collectively contribute to the creation of high-quality lead-acid batteries.

The battery manufacturing process encompasses a series of meticulously designed steps, starting from
the preparation and analysis of raw materials to the final assembly and testing of the finished products.
Each step is a critical link in the chain that ensures the batteries meet strict performance, safety, and
durability standards.

From the initial grid production and pasting, where active material is carefully applied to the grids, to
the subsequent curing, formation, and assembly processes, the level of attention to detail and
adherence to precise parameters is evident. These processes are meticulously executed to optimize
the batteries' electrochemical reactions, capacity, and overall performance.

The testing phase, both for raw materials and in-operation materials, stands as a cornerstone of the
quality control system. Rigorous analysis and continuous monitoring during battery operation help
identify deviations, ensure consistency, and enhance the battery's long-term reliability.

Through my exposure to the laboratory practices, testing protocols, and manufacturing procedures, I
have come to appreciate the complexity of battery production. I have also realized the vital role that
teamwork, precision, and dedication play in achieving a successful outcome. The collaboration
between different departments, from research and development to quality control and production,
exemplifies how a cohesive approach contributes to producing batteries that meet the high
expectations of customers.

Overall, this internship has given me not only a comprehensive view of battery manufacturing but also
a hands-on understanding of the importance of quality control, safety protocols, and the pursuit of
continuous improvement. I am confident that the knowledge and experience gained during this
internship will serve as a strong foundation as I move forward in my academic and professional journey
within the field of energy and manufacturing. I am grateful for the opportunity and look forward to
applying these insights in my future endeavors.

I thank the Exide batteries and their people for welcoming me into such an environment and giving
me an insight into one of biggest battery manufacturers in the world.

Regards,

Muhammad Ahmed Shakeel.

GIK Institute.

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