Production technology

The batteries from ISIC "WESTA" are distinguished by high cold start current performance, minimal water loss during recharge, low self-discharge rate, reliability, and durability, which are confirmed by their enhanced starting characteristics and frost resistance. These batteries are designed for use under harsh operating conditions.

The batteries contain components that ensure their environmental safety and explosion safety.

In terms of their technical and operational characteristics, the batteries produced by ISIC "WESTA" meet the requirements of the European standard EN 50342 and the national standard of Ukraine DSTU GOST 959:2006. Regarding water consumption and self-discharge rate, the company's batteries have the best performance among European manufacturers.

Grid manufacturing

In the production of battery grids, two manufacturing technologies are used:

• Gravity casting method with gas flame protection
• Expansion method of lead-calcium strip
• Using the gravity casting method with gas flame protection, positive and negative grids are produced from lead-antimony alloy with an increased tin content for heavy-duty batteries of the GOLF CAR class.

The equipment used is Wirtz, manufactured in the USA.

The advantages of this technology include good grid strength, battery resistance to deep discharges and recharges. This is especially important for batteries operating under harsh conditions, in energy storage systems from various sources, and for maintaining the energy supply of facilities. Additionally, it is beneficial for use in floor transport (such as stackers, floor machines, etc.) and GOLF CARS.

For the production of positive and negative grids for both light and heavy-duty batteries, the technology of expanding lead-calcium strip is used. This strip is produced through multiple rolling processes on the Strip Line unit by the Italian company SOVEMA:

• From two 15-ton melting pots, one of which acts as a mixer for making the lead alloy, while the other serves as an intermediate pot to ensure continuous operation of the complex
• Slab casting units that create billets with asymmetrical crystallization
• Systems for feeding liquid alloy into the casting unit
• A rolling mill consisting of seven rolling grids
• Devices for trimming the edges of the strip
• Devices for feeding the strip onto a winding unit
• Devices for winding the strip into a roll
• Devices for placing the roll onto a special transport pallet.

A self-produced lead-calcium alloy is used for strip production.

This technology allows the production of batteries with varying grid thicknesses and widths, enabling the variation in the number of plates and thus creating batteries with different starting currents within the same casing. Increasing the number of plates in the battery improves its starter characteristics.

The use of plate block fixators in heavy-duty batteries not only triples vibration resistance compared to the requirements of GOST 531-2020 (IEC 60095-1:2018) class V2 but also allows the implementation of the Performer technology during the production of heavy-duty batteries.

This described method of grid manufacturing significantly enhances the corrosion resistance of the grids while reducing the consumption of lead alloy in the battery.

The process of lead powder production

The oxidation of lead and formation of lead powder takes place in automatic ball mills by SOVEMA and CAM, loaded with lead cylinders.

This technology ensures a stable quality powder with a specific oxidation level.

From the storage hopper, the lead cylinders are fed into the mill's loading tray via a conveyor, and from there into the mill drum.

The oxidation of lead and removal of the resulting powder from the drum are carried out by an air stream.

After exiting the mill, the air stream passes through a series of settling devices (filter system) where it is cleared of lead powder.

The lead powder from the process filter is collected into a screw conveyor, and upon exiting, it is the finished product.

The powder is then transported by an elevator and a screw conveyor system to the lead powder storage hoppers.

This production process is environmentally friendly.

Production of electrode plates. Pastes coating.

In factories, an innovative method of manufacturing electrode plates is employed, based on the use of vacuum technology for preparing lead pastes in mixers from the German company Eirich. Thanks to Eirich mixers, the paste exhibits high uniformity and increased reactivity, ensuring excellent adhesion to the grid.

This technology employs a precision double-sided high-speed pasting machine on a rigid metal drum. The pasting line includes the following automatic SOVEMA devices:

• Unwinder for lead strip
• Strip end welding device
• Strip accumulator for continuous line operation
• Performer 500 Plus for obtaining expanded continuous grids with width stabilization in start/stop mode
• Distribution machine
• Tunnel dryer
• Vacuum stacker, ensuring careful handling of the pasted plate and precise - high-accuracy - stacking into grids

This line ensures stability of characteristics, both of lead pastes and of the weight and geometric characteristics of electrode plates, as well as increased paste adhesion to the grid.

From the pasting machine, electrode plates move onto the strip of the drying unit.

The maturing and drying process

The pasted plates undergo maturing and drying, based on the application of intensive maturing methods. To implement this technology, Catelli maturing chambers from Italy are used, equipped with a function to maintain elevated humidity (90%) at increased temperatures (90°C). In the chamber, the electrode plates are initially kept in an atmosphere of warm and humid air, and then they are dried.

Battery assembly line

After maturation, the plates move onto the assembly line. Implemented at both plants, the assembly line is the latest modification of assembly complexes developed by VM Company for battery capacities ranging from 38 to 100 Ah. The battery assembly line operates in full automatic mode, without the need for direct involvement of workers.

During the line's operation, a worker performs:

• General control over the operation of units and mechanisms
• Feeding of component parts (electrode plates, separator strips, monoblocks, covers) into special accumulators

The new assembly line allows for:

• Increasing the productivity of battery assembly by 2-3 times – 6 batteries per minute
• Improving the quality of assembly operations and battery reliability
• Significantly improving the sanitary and hygienic conditions for the enterprise.

Formation Process

After assembly, the batteries are transferred to the formation area with water cooling, where an innovative formation technology using pulse and reverse currents is applied.

The formation of the batteries takes place on formation roller conveyors with water cooling from the Italian companies Jovis Alia Messapica and NBE O.M. Impianti. Converters from "Digatron" company, manufactured under the patents of MNVK "VESTA", are used to supply power.

This technology allows the formation cycle to be reduced to 12 hours, enhances the quality and stability of battery characteristics, and improves the initial electrical performance of batteries after formation by 5%.

To implement the formation technology using pulse and reverse currents, current converters according to the developments of the "WESTA" corporation are required, as well as additional equipment for processing, servicing, and quality control of batteries.

Completion of the Formation Cycle

After completing the formation cycle (battery charging), the Digatron converter performs a brief battery discharge to remove polarization from the electrode surfaces.

Subsequently, the batteries are transferred from the formation baths to the finishing processing line, where:

• Electrolyte level control and adjustment are conducted.
• Plugs and flame arrestor plugs are installed to ensure safe battery operation.
• Washing and drying are performed to remove traces of various substances used in the battery manufacturing process.
• Marking is applied, including thermal labels indicating the battery type, its structural features, and manufacturing period.
• Charge level and defect presence are checked, with the battery being tested for charge level and load capacity. All batteries undergo 100% quality control with additional patented criteria. The control system detects minimal deviations in battery construction or defects incurred during previous stages of production.
• Hardware is installed, and labeling is applied. The battery receives a label indicating the trademark and main electrical characteristics, and all necessary hardware (handle, terminal, or cap, strap, etc.) is installed

After undergoing such rigorous selection, the probability of deviations in battery performance is practically zero.

Since the implementation of this criterion, the percentage of claims has decreased to 0.3% and continues to decline.

The finished products are palletized for shipment to the finished goods warehouse.

Storage

The finished batteries are transported to the finished goods warehouse, where a computerized tracking system is in place. Product shipments are carried out via road, rail, and maritime containers.

The warehouse is equipped with loading docks, gateways with transitional bridges, enabling loading directly from the warehouse premises.

Material handling equipment from manufacturing companies such as "STILL" and "Toyota" are employed at the warehouse.