Model ZHZM120 Medium‑Density COS Machine

The ZHZM120 medium‑density casting‑welding machine is one of our specialized self‑developed manufacturing machines for lead‑acid batteries. It adopts a four‑station rotary structure with quick and convenient mould replacement to reduce labor intensity. Equipped with PLC automatic control and HMI, it features simple operation, reliable performance, powerful functions and high production efficiency.

Technical Specifications

1. Production Capacity: 60–120 units per hour (cutting labor requirement by half)
2. Power Rating: 120 kW
3. Pneumatic Supply: 0.6–0.8 MPa; air consumption: 2.4 m³/h Cooling Water: 0.5 MPa
4. Overall Dimension (L × W × H): 3000 × 2500 × 2100 mm

Equipment Features

1. The main unit adopts a pneumatic intermittent rotary‑lifting turntable mechanism, which drives four sets of pneumatic clamps to rotate for clamping and transferring pole groups across four stations.
2. The turntable lifts once for every 90° rotation and cycles sequentially through four processes: pole group loading, lug trimming / brushing and flux application, mould cast welding, and pole group unloading.
3. Station 1 – Pole Group Loading: Consists of a cylinder‑driven lifting pallet and pneumatic clamps. During operation, the lifting pallet cooperates with the pneumatic clamps on the turntable to manually load and clamp pole groups and rotate the clamps by 180°, finishing loading to prepare for the next station.
4. Station 2 – Lug Brushing and Flux Dipping: Composed of a cylinder‑driven lifting pallet, pneumatic clamps, reciprocating platform (milling cutter, steel wire brush and flux tank), and trimming unit. It trims pole lugs first, removes oxide layers with steel wire brushes, and then evenly applies flux onto lugs by flux‑soaked brushes. This process runs automatically.
5. Station 3 – Cast Welding: Comprises cylinder lifting unit, pneumatic clamps, mould, demoulding mechanism, lead melting furnace, lead pump and cooling system. The performance of this station directly determines the quality of cast‑welded pole groups. This process runs automatically.
6. Station 4 – Pole Group Unloading and Jar Loading: Built with a cylinder‑driven lifting pallet and pneumatic clamps. The clamps, previously rotated by 180°, return to their home position; then the clamps release, letting finished pole groups drop onto the pneumatic lifting pallet. Operators take out the pole groups and load them into battery jars to complete the whole welding cycle.