Solar Power World heard the that Trojan Battery won an award from Frost and Sullivan for using something called Cast-On-Strap (CoS) equipment to manufacture their batteries. After scratching our heads for a while, we decided just to ask them what the heck that meant. Thankfully, Gordon Beckley, Trojan Battery Senior Vice President of Engineering & Quality Assurance, agreed to explain it to us.
SPW: Congratulations on making Frost and Sullivan’s 2013 Manufacturing Leadership 100 Award (ML100) in the category of “Innovative Enterprise.” Can you tell us about the list?
GB: The Manufacturing Leadership 100 Awards honor companies and individuals that are shaping the future of global manufacturing. Trojan’s receipt of the 2013 ML100 Innovative Enterprise Award was based on the evaluation of the company’s manufacturing achievements by an independent panel of expert judges and peers in the industry. Trojan Battery’s recent manufacturing successes and innovations were benchmarked against a number of other companies competing for this same recognition.
Manufacturing Leadership 100 Award winners will be honored on May 15 in Palm Beach, Fla. at the ninth annual Manufacturing Leadership Summit.
SPW: What did they recognize Trojan Battery for?
GB: Trojan Battery has been awarded its 2013 Manufacturing Leadership 100 Award (ML100) in the category of “Innovative Enterprise” for its innovative use of technology and equipment at its Lithonia, Ga. manufacturing facility. Since the manufacture of deep-cycle batteries for any market, including renewable energy, takes precision, accuracy and succinct methods to ensure the proper assembly of the delicate internal components, Trojan implemented specially designed Cast-On-Strap (COS) equipment to ensure the proper placement and connectivity of deep-cycle battery features, which ensures the highest level of product quality.
This award reinforces Trojan’s strategy of combining advanced manufacturing technology, premium components, and exacting standards for quality to ensure our batteries provide renewable energy customers with the performance and reliability Trojan has become known for over the past 85 years.
SPW: What is Cast-On-Strap equipment?
GB: Trojan’s automated COS machines play a critical role in ensuring the correct placement and connection of a battery’s key components. While COS is used by many battery manufacturers, the technology was originally designed for production of automotive batteries. Recognizing the importance of properly designed COS equipment for deep-cycle battery manufacturing, Trojan commissioned the development of completely new COS technology and machinery specifically engineered for use in the production of its industry-leading, deep-cycle battery products.
The deep-cycle battery plates are stacked automatically into groups and each group is then moved down to the COS machine where the group is leveled and aligned several times in various processes to properly position the lugs of each plate. These precise leveling techniques ensure the proper connection of the plates in the final COS process. The plate connections are then prepped by brushing the lugs, applying a water-based flux and then “tinned” prior to moving on to the casting operation.
The lead used in the casting operation is pumped into the COS mold which is designed to allow the excess lead to quickly drain off leaving the required cast level. The plate lugs are then immersed in the molten lead and then the casting is cooled and the elements are removed from the mold with all strap connections in place. These strap connections now provide a series circuit between the lead plates which results in the proper operation of the battery.
The assembled elements are moved into the final production process where they are inserted into the appropriate battery cases. Each element is then tested for potential shorts, then intercell connections are welded, and the lids are positioned and heat sealed. The terminal burns are performed and the battery is air tested for leaks. The battery receives an assembly code and is filled with the appropriate specific gravity of acid in preparation for the formation process. The battery receives its initial charge during the formation process. After formation, the battery goes through the finishing process where it is cleaned, tested, labeled, and palletized.
SPW: How does it improve Trojan’s manufacturing ability?
GB: Manufacturing excellence is a critical component to Trojan’s goal of building industry-leading quality into our products. As technology advances, so do operations best practices and manufacturing processes. Trojan’s objective was to implement state-of-art equipment that would allow the company to continue to outperform our competition and meet the increasing demands of renewable energy customers, in both quality and innovation.
Trojan has significantly improved its battery assembly process through its COS and automation strategy. With the repeatability of the new processes, Trojan is able to provide a consistent, high-quality product to the renewable energy marketplace. It has also reduced the amount of scrap generated in the past, thus providing more efficiency for Trojan and more product availability for our customers.
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batteryguy31 says
Trojan is only about 15 years late in the game. Well respected manufacturers like Crown Battery have been using COS machines to build best in class deep cycle batteries for well over 15 years.