BATTERIES
Definition:
A battery is a device consisting of one or
more cells, in which chemical energy is
converted into electricity or electrical
energy and used as a source of power.
An electric battery is a device
consisting of one or more
electrochemical cells with external
connections provided to power electrical
devices.
Battery Functions
Engine Switched
Off
When the engine
is switched off,
the Battery
energy is used to
operate the
lighting and
accessory
systems.
Engine Starting
During the starting of an engine, the Battery
energy is used to operate the starter motor and to
provide current for the ignition system during
cranking.
Engine Running:
When the engine is running, the Battery
energy may be needed when the vehicle’s
electrical load requirements exceed the
supply from the charging system.
Voltage Stabilizer
In addition, the battery also serves as a
voltage stabilizer, or large filter, by
absorbing abnormal, transient voltages in
the vehicle’s electrical system. Without this
protection, certain electrical or electronic
components could be damaged by these
high voltages.
Battery Types
The Two main categories or types of cells
(batteries) are as follows:
Primary cells
Secondary cells
Primary cells
A primary cell or battery is one that cannot
easily be recharged after use, and are discarded
following discharge. Most primary cells utilize
electrolytes that are contained within absorbent
material or a separator (i.e. no free or liquid
electrolyte), and are thus termed dry cells.
The chemical reaction totally destroys one of
the metals after a period of time. Small
batteries for flashlights and radios are primary
cells.
Secondary cells
A secondary cell or battery is one
that can be electrically recharged
after use to their original pre-
discharge condition, by passing
current through the circuit in the
opposite direction to the current
during discharge.
The metals and acid mixture change
as the battery supplies voltage. The
metals become similar, the acid
strength weakens. This is called
discharging.
Therefore, Automotive lead-acid
batteries are secondary cells.
Secondary cells for Automotive
applications
The secondary cells that have been
commonly used for automotive applications
include the following;
• Wet-charged
• Dry-charged
• Low-maintenance
• Maintenance free
Wet-charged
The lead-acid battery is filled with electrolyte
and charged when it is built. During storage,
a slow chemical reaction will cause self-
discharge. Periodic charging is required. For
Toyota batteries, this is every 5 to 7 months.
Dry-charged
The battery is built, charged, washed and
dried, sealed, and shipped without
electrolyte. It can be stored for 12 to 18
months! When put into use, it requires
adding electrolyte and charging for 10 to 12
hours.
Low-maintenance
Most batteries for vehicles are
considered low-maintenance
batteries. Such batteries are
built to reduce internal heat
and water loss. The addition of
water should only be required
every 15,000 miles (24,
000km) or so.
The construction of a low
maintenance battery is
similar to a conventional type,
except the change in the grid
material from lead antimony
alloy to lead-calcium.
MAINTANANCE FREE
A maintenance-free vehicle
battery is one that is not
designed to be opened or
refilled. The liquid solution in
conventional lead-acid
batteries can evaporate,
lowering the level in the
battery and rendering it
inoperable.
Typically, a maintenance-free
battery uses a specialized
system, such as a glass mat
or gel, to absorb and
immobilize the electrolyte,
preventing it from converting
to a gas and escaping the
battery.
THANK YOU!
o END OF PART I
CONSTRUCTION OF
BATTERIES
The battery has
the following
parts:
Case
Container which holds and protects all
battery components and electrolyte,
separates cells, and provides space at the
bottom for sediment (active materials
washed off plates). Translucent plastic cases
allow checking electrolyte level without
removing vent caps.
Cover
Permanently sealed to the top of the case;
provides outlets for terminal posts, vent
holes for venting of gases and for battery
maintenance (checking electrolyte, adding
water).
Plates
Positive and negative plates have a grid
framework of antimony and lead alloy. Active
material is pasted to the grid…brown colored
lead peroxide (Pb02) on positive plates, gray-
colored sponge lead (Pb) on negative plates.
The number and size of the plates determine
current capability….batteries with large
plates or many plates produce more current
than batteries with small plates or few plates.
Separators
Thin, porous insulators (woven glass or plastic
envelopes) are placed between positive and
negative plates. They allow passage of electrolyte,
yet prevent the plates from touching and shorting
out.
Cells
An assembly of connected positive and
negative plates with separators in between
is called a cell or element. When immersed
in electrolyte, a cell produces about 2.1 volts
(regardless of the number or size of plates).
Battery cells are connected in series, so the
number of cells determines the battery
voltage. Therefore, a “12 – volt” battery has
six cells.
Cell Connectors
Heavy, cast alloy metal straps are welded to
the negative terminal of one cell and the
positive terminal of the adjoining cell in an
adjacent compartment until all six cells are
connected in series.
Also known as a head-to-tail connection
Cell partitions
Part of the case, the partitions separate each
cell. They are responsible for making the
compartments
Terminal posts
Positive and negative posts (terminals) on
the case top have thick, heavy cables
connected to them. These cables connect
the battery to the vehicle’s electrical system
(positive) and to ground (negative).
Vent caps
Types include individual filler plugs, strip-
type, or box-type. They allow controlled
release of hydrogen gas during charging
(vehicle operation). Removed, they permit
checking electrolyte and, if necessary,
adding water.
Electrolyte
This is a mixture of sulfuric acid (H2SO4) and
water (H2O). It reacts chemically with the
active materials in the plates to create an
electrical pressure (voltage). And, it
conducts the electrical current produced by
that pressure from plate to plate. A fully
charged battery will have about 36% acid
and 64% water.
Cell Theory
A lead-acid cell works by a simple principle: when two different
metals are immersed in an acid solution, a chemical reaction
creates an electrical pressure. One metal is brown-colored lead
peroxide (PbO2). It has a positive electrical charge. The other
metal is gray colored sponge lead (Pb). It has a negative
electrical charge. The acid solution is a mixture of sulfuric acid
(H2SO4) and water (H2O). It is called electrolyte. If a conductor
and a load are connected between the two metals, current will
flow. This discharging will continue until the metals become
alike and the acid is used up. The action can be reversed by
sending current into the cell in the opposite direction. This
charging will continue until the cell materials are restored to
their original condition.
Basic diagrammatic
presentation
ELECTROCHEMICAL REACTION
A lead-acid storage battery can be partially
discharged and recharged many times.
There are four stages in this
discharging/charging cycle.
1. Charged
A fully charged battery contains a negative
plate of sponge lead (Pb), a positive plate of
lead peroxide (PbO2), and electrolyte of
sulfuric acid (H2SO4) and water (H2O).
2. Discharging
As the battery is discharging, the electrolyte
becomes diluted and the plates become
sulfated. The electrolyte divides into
hydrogen (H2) and sulfate (SO4). The
hydrogen (H2) combines with oxygen (O2)
from the positive plate to form more water
(H2O). The sulfate combines with the lead
(Pb) in both plates to form lead sulfate
(PbSO4).
3. Discharged
In a fully discharged battery, both plates are
covered with lead sulfate (PbSO4) and the
electrolyte is diluted to mostly water (H2O)
4. Charging
During charging, the chemical action is
reversed. Sulfate (SO4) leaves the plates and
combines with hydrogen (H2) to become
sulfuric acid (H2SO4). Free oxygen (O2)
combines with lead (Pb) on the positive plate
to form lead peroxide (PbO2). Gassing occurs
as the battery nears full charge, and
hydrogen bubbles out at the negative plates,
oxygen at the positive.
Chemical Action
Discharging
PbO2 + H2SO4 + Pb PbSO4 + 2H2O + PbSO4
+ Electrical charging
energy
Electrolyte
The electrolyte in the battery consists of 35-
40% sulphuric acid and 60-65% water in a
fully charged battery depending on the
manufacturer's specifications. The electrolyte
in a fully charged battery has a specific
gravity or relative density of 1.25 -1.280.
On the other hand a discharged battery may
have its specific gravity even below 1.2 and
each cell producing 1.8 V or less.
Workshop tasks
Battery physical inspection
Voltage output Testing
Specific gravity testing using hydrometer
Charging and discharging
Load testing
Grid framework
The plate grid is a framework of lead antimony with
horizontal and vertical bars. The plate grids are
made into plates by applying the lead paste on
them. In the battery, several similar plates are
properly spaced and welded to form a plate group.
Plates of two types are used, one for the positive
plate group and the other for the negative group. A
positive plate group is rested with a negative plate
group. Separators are placed between the plates so
that the negative and positive plates do not touch
