BAHIR DAR POLY TECHNIC COLLEGE

DEPARTMENT OF AUTOMOYIVE TECHNOLOGY

MANEGMENT LEVEL 5

ASSESSMENT OF CAR BATTEREY MODIFICATION, COMPONENT,

FABRICATION, REPAIR AND MAINTENANCE AND E.T.C

PREPARED BY;

NO NAME OF MEMBERS

1 GIRMA ENDESHAW
2 JEMBERU FIKAD
3 DEREJE DEMELASH
4 YONAS ADUGNA
5 MESFIN TEGEGN
6 TESFAHUN ASMARE
7 BELAYENEH YALEW
1.INTRODUCTION
An automotive battery or car battery is a rechargeable battery that is used to start
a motor vehicle. Its main purpose is to provide an electric current to the electric-powered
starting motor, which in turn starts the chemically-powered internal combustion engine
that actually propels the vehicle. Once the engine is running, power for the car's electrical
systems is still supplied by the battery, with the alternator charging the battery as
demands increase or decrease.

Car batteries are energy storage devices, storing their energy in chemical form. The
most common is the flooded lead-acid battery. Alternating plates of lead, the
anode, and lead oxide, the cathode, are submerged in a bath of sulfuric acid
electrolyte, or “battery acid.” Each cell holds 2.1 V, and car batteries are made of
six cells, so the typical “12 V” car battery holds 12.6 V at full SOC. Less common
AGM (absorbed glass mat) car batteries also use six lead-acid cells, not a liquid
electrolyte, but a gel electrolyte trapped in fiberglass mats. lead-acid batteries are
the most recycled commodity on earth to date, and no other battery is as reusable
as the lead-acid battery.” They’re very heavy, they’re large, and they’re ancient
technology.

1.1 CAUSES OF CAR BATTREY FAILUR

Our automobiles are our lifelines, and it’s tough to imagine our life without them. They
are the most common mode of commutation for daily travelers. Mostly everybody must
have experienced a common scenario at some point in life when we tried to switch on our
car, and it failed to start. Be it our vehicle or a taxi; a battery always can fail at the most
inopportune moments.

Do you still think that battery is just a small part of an automotive? You will be surprised
to know that a battery, though a small part of the framework, is the heart of our machine.
So, for a part so critical, we need to make an informed decision. We need to get into the
depth of knowing the causes of car battery failures. It will be useful for us to understand
the working of our car better and will help us in selecting the right battery next time. The
following are some causes of car battery failures

1.1.1 High temperatures

A chemical reaction occurs in a vehicle battery, resulting in the production of energy. In

hotter settings, this process accelerates, but in colder conditions, it slows down. High
temperatures beneath the hood are the number one cause of automobile battery failure.

1.1.2 Ageing

Everything on this earth is perishable, and so are our batteries. As time progresses, the
internal resistance of the batteries increases, and ultimately it leads to battery failures.

Also Read: How to Check the Condition of Your Vehicle’s Battery

1.1.3 Improper care

Our batteries need proper maintenance and care, even when they are not in use. Improper
care is a fundamental reason for battery failures. One should read the manufacturer’s
instructions about how to store and maintain the battery, when not in use.

1.1.4 Corrosion

Battery acid is corrosive. The battery terminals are the way the battery can get charged by
the alternator. So, if the connections are all swamped up, the battery is not getting
properly charged. One needs to clean the corrosion to improve the car’s ability to charge
the battery.

1.1.5 Cold Weather

It is one of the most common causes of battery failure. Therefore, many people associate
a dead battery with winter. As no one can control the weather, look out for the sign of a
weak battery and make the required preparations.

1.1.6 Electric leakage

All batteries tend to lose electrical energy when not in use, known as self-discharge. It
could be due to several factors like manufacturing practices, ageing, operating
temperature, charge/discharge cycle etc.

1.1.7 Repeated Cycling

When a battery goes from fully charged to fully discharged repeatedly, it loses a lot of
active materials from the positive plates. Thus, reducing its capacity and useful life.

The lifespan of a battery is limited, but it can be considerably shortened by these factors
which tend to cause premature battery failures. The factors stated above are the most
common causes of battery failures, and as a car owner, we can be aware of these factors.
As a matter of fact, in Japan, battery failure is the most significant complaint among the
car owners. A car is driven mostly on a congested road. Due to this, the batteries are
never fully charged, and sulfation occurs.
If your car battery is more than three years old and you live in a hot climate, then your
battery is probably living on borrowed time. Abnormally slow cranking, especially on a
cold day, is another good indication that your battery is going bad. Life guard automotive
batteries are all about delivering the best experience in any road condition. They are
designed for the extraordinary performance of your vehicle in all weather conditions.
They provide high cranking power and best in class warranty to give a long-lasting and
robust battery to its consumers.
1.1.8 battery terminals loose

A loose battery connection affects the flow of current. Therefore, less current is going to
the electrical systems and the vehicle won’t start or start very slowly. Also, a loose
battery connection causes the car’s electrical accessories like car lights, anti-theft system
and audio among others to dim or fail completely.

2. problem of statement
The main problem of car battery is terminal cut off short period life span and acid to
water leakage. this is due to loose connection but not only loose connection but also high
temperature, ageing, improper care and corrosion are some cause for car battery failure.
So in order to overcome this challenge car battery maintenance, repair and modification
are needed.

3. Literature review
In general term, a battery is a device that converts chemical energy into electricity. An
automobile battery is a wet cell battery that contains actual energy that stores chemical
energy and then transforms it into electrical energy on applications.

Apart from various battery designs and specifications, of serve same purposes.
specifically, on automotive batteries, it has six cells with lead storage on each. Each cell
is filled with a sulfuric acid solution, which is known as an electrolyte.

3.1 Design

An automobile battery is an example of a wet cell battery, with six cells. Each cell of a
lead storage battery consists of alternate plates made of a lead alloy grid filled with
sponge lead (cathode plates) or coated with lead dioxide (anode).[14] Each cell is filled
with a sulfuric acid solution, which is the electrolyte. Initially, cells each had a filler cap,
through which the electrolyte level could be viewed and which allowed water to be added
to the cell. The filler cap had a small vent hole which allowed hydrogen gas generated
during charging to escape from the cell.

The cells are connected by short heavy straps from the positive plates of one cell to the
negative plates of the adjacent cell. A pair of heavy terminals, plated with lead to resist
corrosion, are mounted at the top, sometimes the side, of the battery. Early auto batteries
used hard rubber cases and wooden plate separators. Modern units use plastic cases and
woven sheets to prevent the plates of a cell from touching and short-circuiting.

In the past, auto batteries required regular inspection and maintenance to replace water
that was decomposed during the operation of the battery. "Low-maintenance" (sometimes
called "zero-maintenance") batteries use a different alloy for the plate elements, reducing
the amount of water decomposed on charging. A modern battery may not require
additional water over its useful life; some types eliminate the individual filler caps for
each cell. A weakness of these batteries is that they are very intolerant of deep discharge,
such as when the car battery is completely drained by leaving the lights on. This coats the
lead plate electrodes with lead sulfate deposits and can reduce the battery's lifespan by a
third or more.

VRLA batteries, also known as absorbed glass mat (AGM) batteries are more tolerant of
deep discharge but are more expensive.[15] VRLA batteries do not permit addition of
water to the cell. The cells each have an automatic pressure release valve, to protect the
case from rupture on severe overcharge or internal failure. A VRLA battery cannot spill
its electrolyte which makes it particularly useful in vehicles such as motorcycles.

Batteries are typically made of six galvanic cells in a series circuits. Each cell provides
2.1 volts for a total of 12.6 volts at full charge. [16] During discharge, at the negative (lead)
terminal a chemical reaction releases electrons to the external circuit, and at the positive
(lead oxide) terminal another chemical reaction absorbs electrons from the external
circuit. This drives the electrons through the external circuit wire (an electrical conductor)
to produce an electric current (electricity). As the battery discharges, the acid of the
electrolyte reacts with the materials of the plates, changing their surface to lead sulfate.
When the battery is recharged, the chemical reaction is reversed: the lead sulfate reforms
into lead dioxide. With the plates restored to their original condition, the process may be
repeated.

Some vehicles use other starter batteries. For weight savings, the 2010 Porsche 911 GT3
RS has a lithium-ion battery as an option;[17] from 2018 onward, all Kia Niro conventional
hybrids feature one as well. Heavy vehicles may have two batteries in series for a 24 V
system or may have series-parallel groups of 24 V.
3.2 Components of a Battery
Below are the major components of batteries used in automotive engine engines

 Container – Is a part made of the steel can, used to enclose the substances of the
cell to form a cathode, which is a part of the electrochemical reaction.
 Cathode – is a manganese dioxide and cathode.it is the electrode reduced by the
electrochemical reaction.
 Separators – are the nonwoven, fibrous fabric that separates the electrodes.
 Anode – anodes are electrodes that oxidized. They are made of powered zinc metal.
 Electrolyte – is the medium for movement of ion within the cell. It carries the ionic
current inside the battery. it’s made of potassium hydroxide solution in water.
 Collector – is a brass pin in the middle of the cell that conducts electricity to the
outside circuit.

Chemical reaction of car battery will be like this

Hint, Car battery function: Chemical energy becomes electrical energy

A car battery stores energy in chemical form and converts it into electrical energy. In this
electro-chemical process, four materials react with each other:

 Hydrogen (H)

 Oxygen (O2)

 Lead (Pb)

 Sulfur (S)

Connection of an external consumer starts the chemical reaction in the battery:

 The electrolyte, a mixture of sulfuric acid (H2SO4) and distilled water decomposes
into positively charged hydrogen ions (H+) and negatively charged sulfate ions
(SO42-).

 At the same time, electrons (2e–) travel from the negative to the positive electrode
via the external consumer.

 To compensate for this flow of electrons, sulfate ions travel from the electrolyte
into the negative electrode, where they react with the lead (Pb) to produce lead
sulfate (PbSO4).

 Lead sulfate is also produced in the positive electrode: The bonding of oxygen
(O2) in the lead oxide (PbO2) is broken by the transfer of electrons and the oxygen
passes into the electrolyte. The remaining lead (Pb) bonds with the sulfate (SO 4)
from the electrolyte.

 There, the oxygen bonds with the hydrogen to form water (H 2O). As the sulfuric
acid is used up by the formation of lead sulfate, the concentration of the electrolyte
 solution reduces. When the concentration of the sulfuric acid falls below a certain
level, the battery has to be recharged.

During charging, the chemical processes take place in the reverse sequence. At the
end, the original elements can be found: The positive electrode consists of lead
sulfate (PbSO4), the negative electrode consists of pure lead (Pb) and the electrolyte
consists of dilute sulfuric acid (H2SO4). As this conversion process is associated
with losses, a battery can only withstand a limited number of charging cycles.

3.3 Characteristic of a Battery

Below are the characteristics of battery used in automobile engine:

 Available in a variety of sizes.

 Moderately good high and low-temperature performance.

 Electrically efficiently

 Good float operation.

 Low-cost battery and can be produced anywhere on a local basis.

  The high open-circuit voltage of all aqueous electrolyte battery systems.

 Good charge retention for intermittent charge applications.

 Cells are easily recycled.

3.4 Types of Battery

Below are the types of battery used in automobile and other components:

Starting, Lighting, and Ignition Batteries:

These types of battery are abbreviated SLI, it’s vastly used in automotive. Just as its
name implies, it is used for starting a car and also provide power to the ignition. The
battery also powers electrical components such as radio, headlights, etc. of a vehicle.
STLs have a shallow charging circle, which means the time it takes to run down and get
charged again.

3.3.1 Sealed Batteries

This term can refer to many different structures, including slight modifications to the
submerged style. In this case, even if the user cannot enter the battery compartment, the
internal structure is still basically the same as the flooded battery. The only difference is
that the manufacturer has ensured that there is a sufficient amount of acid in the battery to
maintain the chemical reaction under normal use throughout the battery warranty period.
Other types of lead-acid batteries are also sealed, as described below. Very popular uses
are engine start and limited start/deep cycle applications.

For this type of battery, the typical absorption voltage range is 14.2 to 14.7 volts; the
typical floating voltage range is 13.1 to 13.4 volts.
3.3.2 Deep Circle or deep cycle Batteries

The deep cycle battery is a type of lead acid battery and can be flooded or sealed. It uses a
thicker battery plate in its cells and has a denser active material. The deep cycle battery
type is designed for sustained power with a lower current draw over extended time periods.
It’s better suited to recreational vehicles, golf carts and marine vehicles which is why it’s
also called a marine battery.
3.3.3
Valve Regulated Lead-Acid Batteries:
These types of batteries are designed to be low-maintained as it does not require regular
addition of water to the battery cell. Because of this, the battery is sealed leaving no
chance for maintenance or servicing. It’s to be replaced when spoiled.

The valve-regulated lead-acid battery is of two types; Absorption Glass Mat (AGM) and
Gel Cell batteries. The AGM supplies high rate of power in a short burst compared to
other sealed versions. This is because of the fast reaction between the electrolyte and thin
fiberglass surface mat.

On the hand, the Gel cell batteries are known for that because of their silica-based
electrolyte. They also work well on deep circle applications like golf carts and marine
vehicles. However, they are less effective on hot or cold temperatures.
3.3.4 Wet Cell (or Flooded) Batteries:
The wet cell batteries are less expensive than other types but require regular
maintenance. It’s named wet cell because it contains a liquid substance, often a
combination of lead, sulfuric acid and water. This help to create the required
electrolyte that may lose over time of usage.

3.3.5 Lithium-Ion (Li-Ion) Batteries:

Modern automobiles such as electric and hybrid cars use the lithium-ion battery. The
battery is able to store significantly more energy and has less weight compared to
traditional lead batteries. However, Li-ion batteries generally have low lifespans, which
one of the major drawbacks, a maximum of three years regardless of use.
3.5 Batteries Specifications
Below are the specifications that can see on various types of batteries:

 Physical Design – batteries are specified by their sizes, types, and location of their
terminals as well as mounting style.

 Amp-hours (Ah) – an ampere-hour is a unit related to the energy storage capacity of

the battery.

 Cranking Amperages – is the amount of current a battery can offer at cold cranking
ampere which is 0-degree Fahrenheit (– 18 degrees Celsius). The cranking amperes
is the amount of current a battery can provide at 32-degree Fahrenheit which is 0
degree Celsius.
  Reserve Capacity Minutes (RCM) – this is the ability for the battery to sustain a
minimum stated electrical load.

 Group Size – this is the physical dimension such as weight, height, length, and width
of a battery. it’s often stated by manufacturers.

 Data codes – the data code help buyers to know if the battery they are buying is the
recently released version.

3.6 Working Principle

the working of automobile batteries is less complex and interesting. Most of it relies on a
lead-acid chemical reaction to power the electrical components. The SLI is the type
mentioned, it provides short bursts of energy in order to power the accessories, and
importantly the engine starter motor. It starts the battery and as soon as the engines begin
to run, alternator returns charge to the battery. Just imagine a battery as a power plant that
converts a chemical reaction into electrical energy. Typically, SLI batteries have six cells,
containing two plates at each. One of the plates is made of lead and the other with lead
dioxide. Each cell can produce about 2-volts of energy. The plates are submerged in
Sulphur acid that allows the two plates to react. This acid will trigger a reaction on the
lead dioxide plate causing it to create ions and lead sulphate.

The irons created by the lead dioxide plate react to the other plate to produce lead
sulphate and hydrogen. This result in a chemical reaction that produces electrons, the
electrons move around the plates and generate electricity. The electricity flows out
through the terminals to start the car and power other electrical components of the car.
The battery can be jumpstart because the chemical reaction process is entirely reversible.
This is why the engine alternator can continue to charge the engine throughout the
duration of its life. Typically, starting uses less than three percent of the battery capacity.
For this reason, automotive batteries are designed to deliver maximum current for a short
period of time. They are sometimes referred to as "SLI batteries" for this reason, for
starting, lighting and ignition. SLI batteries are not designed for deep discharging, and a
full discharge can reduce the battery's lifespan.

As well as starting the engine, an SLI battery supplies the extra power necessary when
the vehicle's electrical requirements exceed the supply from the charging system. It is
also a stabilizer, evening out potentially damaging voltage spikes. While the engine is
running most of the power is provided by the alternator, which includes a voltage
regulator to keep the output between 13.5 and 14.5 V. Modern SLI batteries are lead-
acid type, using six series-connected cells to provide a nominal 12-volt system (in most
passenger vehicles and light trucks), or twelve cells for a 24-volt system in heavy trucks
or earth-moving equipment, for example.

Gas explosions can occur at the negative electrode where hydrogen gas can build up due
to blocked battery vents or a poorly ventilated setting, combined with an ignition
source. Explosions during engine start-up are typically associated with corroded or dirty
battery posts. A 1993 study by the US National Highway Traffic Safety
Administration said that 31% of vehicle battery explosion injuries occurred while
charging the battery. The next-most common scenarios were while working on cable
connections, while jump-starting, typically by failing to connect to the dead battery
before the charging source and failing to connect to the vehicle chassis rather than
directly to the grounded battery post, and while checking fluid levels. Close to two-thirds
of those injured suffered chemical burns, and nearly three-fourths suffered eye injuries,
among other possible injuries.

 3.7 Functions of Battery

Below are the functions of battery in automobile engines:

 The primary functions of battery in automotive engines are to power the starter
motor so as to run the engine.

 All electrical components in a vehicle rely on the battery.

  In modern cars where most parts like the injector system, spark plug, sensors are
also powered by the battery

The applications of battery in gasoline and diesel internal combustion engines. Their
category of battery is referred to SLI batteries, serving the purpose of starting, lighting,
and ignition on vehicles. while starting the engine, the SLI battery types supply the extra
power necessary when the electrical parts in a vehicle require excess power above the
supply of the charging system. This feature can also be called a stabilizer.

Special types of battery are used to power electric and hybrid cars. they use high-voltage
electric vehicle battery, but the automotive battery can also be used as well. This allowed
the used of standard automotive electrical parts that are designed to run on 12 volts.
These types of battery are also called auxiliary batteries.

The electric vehicles (EVs) don’t charge the auxiliary batteries like the conventional
internal combustion engines that use the alternator to boost their batteries while running.
electric vehicles use a DC-to-DC converter to controls the voltage to the required float-
charge voltage.

Let’s take a look at the five functions of a car battery and discover just how sophisticated
a car battery is.

 The car’s power storage A car battery is the car’s power bank. The often rectangular,
box-shaped battery is the storehouse for the power your vehicle needs to start the motor
and maintain a charge.
On the outside, a car battery just looks like a boring plastic block with some connectors
on the top. But this plastic outer shell is quite durable and usually acid-resistant, to
protect the complex inner workings and materials inside that do the magic. The inside of
the battery is home to a chemical solution (usually sulfuric acid) and layers of lead and
lead dioxide plates, which react with the acid to create energy.
 There are different voltage levels available for car batteries, the most common being 12
volts. A standard 12-volt car battery has six cells, which each produce 2.1 volts in a fully
charged state. Every decrease of .2 volts in a battery’s charge equates to roughly a 25%
loss of power. Therefore, it is critical to maintain proper battery charge at all times.

There are some things to be aware of that might drain your battery and decrease your
power stores. You certainly don’t want to find yourself running late for work one
morning, and your car won’t start needing a dead battery recharge. Watching out for
these hazards will reduce the chance that you’ll be surprised by a dead battery:
 Don’t leave your headlights on! Most newer model cars have automatic headlights, so
paying attention to this might not even be on your radar. But imagine, you’re driving
someone else’s car, or a courtesy vehicle while yours gets serviced, and it doesn’t have
automatic headlights. You could forget to turn them on, and you could forget to turn them
off! This will drain the battery fairly quickly.
 Make sure all your doors are shut, interior and exterior, and that no lights or electronics
are running. These things are called a parasitic draw, and they slowly leech the power out
of a battery when the car is off because there’s no active recharging coming from the
alternator.
 Regularly check (or have your mechanic regularly check) your battery connections and
terminals. Over time they can jiggle loose or even start to build up corrosion. This is
easily avoidable but can cause damage to your car’s electrical system if you stall out
during your commute.
 If at all possible, don’t leave your car sitting too long in the extreme heat or cold.
Whether you park it in a garage or you periodically start it up and give the battery some
charge, any battery that is moderately aged may start to weaken in harsh temperatures, at
either end of the thermometer.
 If you notice that your car has trouble starting or won’t start after you’ve just driven it
somewhere, for example – you drove to the supermarket and had no problem, but when
you returned to your car with your bags, the car wouldn’t start – you could have a bad
 alternator. To start your car, you need battery power. But while your car is on, the
alternator recharges the battery. So if a single drive seems to drain the life from your
battery, chances are it’s not getting the charge it needs while driving, and you might need
a new alternator.
 Simple factors like age and overuse can wear a battery out, too. If it’s been 3-5 years
without being checked or replaced, start paying a little more attention to it and maybe
have it tested.
 Energy to Start the Engine with its power storage, the battery contains enough power to
start the engine. The acid and the plate materials (lead and lead dioxide) interact in a
specific order to create positive and negative charges as well as byproduct materials.
These components create a chemical reaction which generates electrons – or electricity –
that travels out of the battery to start your car. Fun fact: if you’ve ever used a car charger
to boost your weak car battery, the reason it works is because this sequence of events is
reversible. The charger can put the energy back into your battery.Standard 12-volt car
batteries have varying degrees of power strength. The CCA (or cold-cranking amperes)
rating indicates how well the battery will be able to start an engine in the cold. Depending
on the type of battery you have and the climate you live in, you may or may not have the
necessary amount of battery power to crank your car’s engine.
Many people think “more is better,” so they automatically assume the battery with higher
CCA is the right one. The right CCA for your vehicle largely depends on the climate you
live in. High CCA is great for colder climates where engines might be harder to start.
Batteries with higher CCA have had more plates, and more solution added.

But this design isn’t one-size-fits-all. Adding more plates means they have to be thinner
and closer together. In high-heat climates, this isn’t ideal because it can lead to corrosion
and loss of liquid. CCA is a rating best suited for North America and Europe, where it
gets cold frequently. In other parts of the world where it’s mostly hot all the time, MCA
and HCA are a better gauge.
 It is important to note that a battery’s available power increases in warmer temperatures
because chemical reaction rates are higher. CCA (cold-cranking amps) measures the
current available at -18°C. MCA (marine cranking amps) measures the available power at
0°C, which is more helpful in warmer climates where freezing weather is rare. Battery
cranking power increases by roughly 20% under this rating method.

Then there’s HCA (hot cranking amps), which measures the power available at 26.7°C,
or 80°F. A good rule of thumb is, the warmer the conditions, better the battery will be
able to crank. HCA would be the ideal rating method to use in arid and tropical climates.

Still, it’s not as simple as choosing a battery based on the CA measurement that is most
suitable for your climate. Every vehicle has different loads – or the amount of current
needed from the battery. Size is not necessarily the best indicator, either. A smaller car’s
engine may need as much cranking power as a large SUV because it has to be cranked
faster.

Each of the vehicle’s options, from power windows to heated seats, places a demand on
the current needed from the battery. Fuel type is a factor as well. So, just because you live
in a cold climate and you have a newer vehicle with all the bells and whistles, does that
mean you should choose the battery with the highest possible CCA you can find?

Maybe not. Higher CCA is linked to possible starter damage and can shorten the life of a
battery. Ask your local auto body shop which battery will provide you with the best
balance of power and endurance while sustaining all of your car’s functions in the
weather you most typically experience.

 Delivers Electricity to the Ignition System When you turn on your car’s ignition,
whether you do it by turning a key or pushing a button, you send a signal to the battery,
telling it to initiate that chemical reaction we just talked about in order to produce enough
electrical current to get the starter to power up the engine.
 Basically, the battery’s job in this part of the process is to exude a strong, short burst of
power. The coil then generates the high voltage necessary to crank the starter, reach the
spark plugs via a distributor, and ignite the fuel inside the combustion chambers.

There are various types of ignition systems, but most of the road vehicles we know today
have a mechanically timed ignition consisting of multiple parts that complete a circuit.
There are many processes working in tandem, somewhat simultaneously, and it happens
very quickly, but it starts with the battery. We all enjoy the ease and convenience of
modern automobiles, thanks to a simple battery that acts as the catalyst to a series of
fascinating processes and exchanges of energy.

 Works with The Alternator to Power Electronics

 You may have already known those first three functions, but were you aware that the
battery also works in tandem with the alternator to power your vehicle’s electronic
processes?
That’s right — the alternator (whose job it is to “alternate” the current and turn
mechanical energy into electrical energy) is the component that keeps your radio, air
conditioning, USB and auxiliary-connected devices, and lights running. But the battery
has to provide reliable backup in the event that the alternator becomes overwhelmed.
When too many processes are draining the alternator, the battery sustains the power flow
by providing an energy boost.

Essentially, the alternator is a generator. The battery is what provides the initial burst of
energy to the starter so that it’ll crank the engine. Still, the alternator is what keeps the
electronics going and charges the battery. That’s why a car battery generally won’t go
dead while the car is being driven because it’s actively charged by the alternator. (But if
you ever have a dead battery, don’t worry Mach1 Services is here to help!)
If you’re a visual person, you may want to understand exactly what happens under the
hood of your car to get this generator (alternator) going. There’s a wheel on the alternator
 that gets turned once the car’s engine starts running. The engine spins a set of wheels,
which then spin the wheel on the alternator. It’s like a game of Mouse Trap.

With its stator, rotor, diodes, voltage regulator, and cooling fan, an alternator is
constantly working while your car is running to maintain the energy flow through the
engine and your vehicle. Alternators can last up to seven years in good conditions and
with proper use, but they are also one of the most common reasons for “car trouble.” If
the alternator dies, your car will drain the battery’s power fairly quickly and then die.

 Dashboard battery icon is lit, or system message displays “service battery charging
system”
 Dimmer lights than usual (both interior and headlights) and heated/cooled seats not
working as well
 Grinding sounds – alternators have a lot of parts, like pulleys, bearings, and belts that can
wear out over time
 The smell of burning rubber – this could be the alternator’s belt getting melted by some
other component that’s out of alignment
 The battery helps regulate voltage It’s a well-known fact that power surges can damage
electronics. Well, your battery prevents sudden spikes in power from damaging your
car’s internal computer and ignition system from damage. Along with various types of
fuse elements and circuit protection devices used throughout the vehicle, a car’s battery
can help to regulate the power that goes to the electrical systems. Alternators have
voltage regulators that convert the electrical current into a type of current that won’t
damage the car’s electronics. The purpose of this regulator is to maintain the highest
possible amount of voltage in the circuit consistently. It can signal the alternator to
generate more or less power according to the vehicle’s needs. Any excess power charges
the battery. Having the battery to rely on as a backup for the alternator is what protects
your car’s systems. If you were to suddenly disconnect the alternator from the battery, the
resulting voltage surge would likely damage your vehicle. But the completed circuit, with
the battery in place, ensures a slower, more regulated change in power levels if your
alternator dies and your battery takes over.
3.8 Manufacturing Process of Car Batteries
Ordinary as battery may look, its manufacturing process could be quite complicated. In
this post, we’ll show you how a battery is produced from the very beginning with the
example of the finished vehicle battery. Hope you could know more about the power
source after reading it.

How was a cell of battery born?

The cell is the smallest unit of a battery system. A collection of batteries forms a module,
and then the collection of these modules form a battery pack. This is the basic structure of
the vehicle power battery. Pulping of active materials – mixing process is to stir the
active material into a slurry by a vacuum mixer. This is the first process of battery
production. The quality control of this process will directly affect the quality of the
battery and the qualified rate of the finished product.

Applying the stirred slurry to the copper foil – coating The process is to apply the slurry
that has been stirred after the previous operation to a 4000-meter-long copper foil at a
speed of 24 feet per minute. The copper foil before coating is only 6 microns thick
Pressing and splitting the cathode material on the copper foil – cold pressing and pre-
cutting in the milling workshop, the roller is used to press the pole piece to where the
positive and negative electrodes are attached, and the cold-pressed pole pieces are cut as
per the size of the battery to be produced. Cutting out the positive and negative electrodes
on the battery – die cutting and slitting. The die cutting process is to form a conductive
electrode tab for a battery cell by a die cutting machine. The polar tab is the metal
conductor derived from the positive and negative poles in the cell. The slitting process is
to cut the battery pole piece by a cutter. Finishing the prototype of the battery cell –
winding Combining the positive electrode sheet, the negative electrode sheet and the
separator of the battery into a bare cell in a winding manner. Removing moisture and
injecting electrolyte – baking and injecting Moisture is the enemy of the battery system.
The battery baking process is to make the water inside the battery up to the standard and
ensure that the battery has good performance throughout the life cycle. The injection is to
inject electrolyte into the cell. 3.8.1 The process of cell activation – formation

The formation is a process of activating the cell after the injection, and chemical reaction s inside
the cell, by charging and discharging, form a SEI film (the electrolyte and the anode material
react on the solid-liquid phase, so a passivation film is formed). The process also includes the
second injection of electrolyte, weighing, welding of the injection port and gas tightness testing
after the cell is activated.

3.8.2 Battery pack production process

A single battery cell cannot be used directly. Only when a lot of cells are combined, together
with protective circuits and shells, can they be used directly. This is the so-called battery module.
Feeding The battery cell is transmitted to the setting position, and the robot automatically grabs
it and send it to the mold assembly line. Plasma cleaning process Cleaning the surface of each
cell. Ion cleaning is used here to ensure that contaminants in the process are not attached to the
bottom of the cell. Gluing for the cell Before the cell is assembled, the surface needs to be
glued. This is how the battery is fixed, insulated and dissipate the heat. Welding of end plate
and the side plate The battery modules are mostly made of aluminum end plates and side plates,
which are later laminated and welded by robots. Assembling of wire Harness isolation board
After the welding monitoring system accurately locates the welding position, the material
barcode of the wire harness isolation plate is bound to Manufacturing Execution System,
and a separate encoding is generated for traceability. After the coding, the harness
isolation board is automatically loaded into the module by the robots. Completing the
serial-parallel connection of the battery – laser welding Through automatic laser welding,
the connection between the pole and the connecting piece is completed, and thus the
battery serial parallel is possible an important test before shipping – offline test Check the
full performance of the module before it goes off the production line, including module
voltage/resistance, battery cell voltage, withstand voltage tests, and insulation resistance
test.

3.8.3 Battery pack’s ultimate test – battery pack safety test

In fact, from the initial design stage, electric vehicles have to adopt various methods to ensure
maximum safety. However, the perfect design has to be tested by practice.

3.8.3.1 Fire test

In terms of safety performance, the standard in China is external combustion for 130 seconds,
and the battery can’t be lit up or explode.

3.8.3.2 Vibration test

Vibration test is used to simulate the bumpy road conditions of battery packs in actual use. It is
used to test whether the vibration of battery packs can cause the parts of battery products with
poor quality to loosen or even cause the shell to break down.

3.8.3.3 Impact test

Similar to vibration test, impact test is used to test the mechanical stability of battery pack. It
simulates the impact of instantaneous bump on battery pack structure when a vehicle passes
through a road barrier.

3.8.3.4 Squeeze test

As for the pass standard of extrusion testing, the battery can’t catch fire or explode. If you are
interested in learning more about batteries, please feel free to contact us or leave a comment.
We’d be very happy to hear from you secret processes, which are not bound to be revealed to
masses.

3.9 Environmental impact

Battery recycling of automotive batteries reduces the need for resources required for the
manufacture of new batteries, diverts toxic lead from landfills, and prevents the risk of
improper disposal. Once a lead–acid battery ceases to hold a charge, it is deemed a used
lead-acid battery (ULAB), which is classified as hazardous waste under the Basel
Convention. The 12-volt car battery is the most recycled product in the world, according
to the United States Environmental Protection Agency. In the U.S. alone, about 100
million auto batteries a year are replaced, and 99 percent of them are turned in for
recycling. However, the recycling may be done incorrectly in unregulated environments.
As part of global waste trade, ULABs are shipped from industrialized countries to
developing countries for disassembly and recuperation of the contents. About 97 percent
of the lead can be recovered. Pure Earth estimates that over 12 million Third-
World people are affected by lead contamination from ULAB processing.

3.10 Assembling and disassembling

Assembly process of a battery module and battery pack" deals with both battery module
assembly and battery pack assembly. It was our goal to process and convey the
systematically acquired knowledge about the processes. The brochure is thus intended to
serve as a basis for the planning of assembly lines for battery modules and battery packs.
This publication is the third edition, which has been updated and supplemented with
extensive information. this brochure schematically illustrates the further processing of the
cell into battery modules and finally into a battery pack. The individual cells are
connected serial or in parallel in modules. Several modules as well as further electrical,
mechanical and thermal components are assembled to a pack. Each pack has a different
Layout depending on the required performance. Due to the large number of different
product and process variants, common information on the process parameters cannot be
stated and can be specified in more detail in a joint discussion with the PEM Chair or the
VDMA.
Your car battery does its job unnoticed for the most part, so if you do need to disconnect
it, you might find yourself at a loss. Never fear, how is here! There are a lot of car repairs
that you should really trust to a mechanic, but disconnecting or replacing the battery in a
gas-powered car is not one of them. Whether you're disconnecting your battery
to recharge it, replace it, or for some other reason, you can absolutely do this yourself and
it likely won't take you more than a half hour, so let's get started.

4. Methodology:
This paper will begin with a brief analysis of the battery circuits during its first use in
vehicles and their collection for re-use or recycle. The recollection costs will be estimated
from received offers by battery management integrated systems. There are three main
types of electric cars: Hybrid (HEV), Plug-in Hybrid (PHEV) and full electric (EV).
Second life has sense with big battery packs; therefore, the study will only consider
batteries from PHEV and EV. For these batteries, there are two main strategies to face
rehabilitation. The first one is meant to re-use the batteries without much intervention.
That is, trying to re-use the batteries in the same configuration as it is used in the car:
same shape, same refrigeration systems, same covers… as if it was a black box
(Carranza, 2013). The second one opts to dismount the battery in modules or cells and re-
arrange them in a better configuration for the second use (Cready et al., 2003). Some of
their main characteristics are presented in Table 1. In this work, both strategies will be
analyzed. cost analysis based on recollection costs, functional and health tests, re-
habilitation plant investments amortization and production time costs will be calculated.
Knowing that nowadays, and until at least ten years, the number of batteries available
will still be low, two approaches will be presented: One for a re-habilitation plant using
176 batteries per year at most, where workers are far from being saturated and they have
many waiting or spare time; And another one considering enough batteries to support a
productively better optimized factory. That is:
• For the direct re-use strategy: 6 test benches working simultaneously providing a total
of 1056 batteries per year for both PHEV and EV with one worker per turn.
• For the module reconfiguration: two workers per turn to run 3 test benches for 528
PHEV re-purposed batteries annually and 2 test benches to work on 352 EV batteries.
5. Cost analysis
First of all, we are going to know the price of new car battery. here there are many
types of car battery depending on mark, ampere and volt. for example, 200-amp
heavy duty Trakker battery price is 40000 up to 60000 birr per one battery. but to
rebuild this battery it needs small amount of money, approximately 2500 up to
3000 birr.
Generally, maintenance is good aspect for the user and owner.
6. Conclusions:
Nowadays, new batteries cost near 40000 birr and the expected prices for one battery in
2022. The costs of re-habilitated batteries, no matter which of the strategy, are always
mandatory. The best price obtained is 2500 up to 3000 birr from direct re-use of car
batteries on a high capacity factory. Indeed, it is ten times cheaper than a low capacity re-
worked one. If the number of received batteries is expected to stay above the 500 units
per year it is highly probable to have a profitable business. The difference from our best
price and the expected cost of brand new ones is four times lower. That represents a
substantial potential for second-use batteries to have a niche in the energy storage market.
Anyhow, we can conclude that it’s better not to count much on the module
reconfiguration strategy, at least at the beginning, because there’s not enough margin
between the re-purposed cost and the expected price from new batteries. In fact, the direct
re-use solution clearly takes the lead.
This first approach shows up that results get better when more car batteries are available.
In fact, even the most intensive solution presented has a major manual work.
Industrialization can easily provide lower costs if there are enough re-manufactured
batteries to invest in. Another expected improvement will surely come with a more
efficient battery assessment test, which is something car manufacturers are already
working on. Actually, car manufacturers are also working on the development of a
rebuild prepared for first and second uses which will facilitate their integration in the net.
From the obtained results, we can suggest that re-used batteries will speed up the
entrance of storage systems into grid ancillary services.
To summarize, a car battery is the most crucial element of any car or vehicle responsible
for functioning the other elements of the car or vehicle. Since a battery has a limited
lifespan, you'll need to replace it with a new one in the future, which will invite a
considerable cost. Interestingly, nowadays, the batteries' price ranges are so wide today
than what it was earlier that you wouldn't return home empty-handed. Today's batteries
come in different sizes, types, warranty periods, brands reserve capacity, and much more
to simplify this. And these factors significantly govern the final battery costs.
These are some maintenance that I performed on my garage.
7. Recommendation

7.1 HOW TO ENSURE PROPER CAR BATTERY MAINTENANCE

Your car battery is an essential part of the car’s functionality. The battery lasts between 3
and 5 years, depending on how you use the car.  However, your battery can stop working
before the estimated time for many reasons and one vital way to prevent this is through
proper maintenance. 

Proper car battery maintenance helps you squeeze as much shelf life out of your battery
as possible, as you can foresee any dangers to your battery and diagnose issues early.
This way, you can get optimal functionality before you dispose of it. We will share the
top tips for car battery maintenance below. 

What Your Car Battery Does?  It’s essential to understand what your car battery does to
maintain it well. The car battery helps the car’s engine turn when you turn the ignition.
Also, it is responsible for the electrical circuit and affects light, radio, etc. Most
importantly, the car battery charges and draws power from the engine to power the rest of
the car. 

7.1.1 Why Should You Maintain Your Car Battery? 

Inspecting your battery can help you save money. When you inspect it, you can detect
damage and cracks faster. In doing so, you can avoid full battery leaks and save repair
costs. See how to test your battery for current leakage. 
Tips for Car Battery Maintenance 

 Keep Your Battery Warm 

The simplest form of care you can give your car in the cold weather is to keep the battery
warm. You can keep your car parked in a well-insulated garage. This helps prevent your
car battery from working double during the winter months. You can also prevent the
scorching sun from rusting your battery too quickly. However, abstain from heated
garages as they can also rust your car battery. 

 Minimize the Use of Electronics

You should enjoy the benefits of your car, like the radio and air conditioning, but it’s best
to minimize the use of these things when the car isn’t running. If you have to leave your
car for more than five to ten minutes, switch off these appliances. Using them when the
engine isn’t running may cause more wear and tear on your battery. 

 Double-check the Lights 

You should double-check the interior cabin lights and your headlights to ensure nothing
is on when leaving your car. These seemingly small things can weaken your battery
overnight. Also, remember to unplug all accessories. 
  Don’t Leave Your Car Inactive 

Your car battery can typically go without use for two months; however, this is far from
ideal. An inactive car means the battery isn’t charging, so it’s best to take your car for at
least a thirty-minute drive once a week if you are not a regular user. If you leave your car
unused for an extended period, check the charging and electrolyte level before you set
out.

 Check the Acid Level 

It’s best to check the Acid Level of your car battery once every six months. If you drive
only short distances but often use the air conditioner and lights, or park your car for an
extended period, you need to be wary of acid stratification. Acid stratification occurs
when your battery doesn’t receive a full charge often or has a shallow discharge. Your
battery should mostly reach an 80 percent charge for it to function well and often staying
below this may mean the electrolytes will remain at the bottom and won’t get to the top
of your battery. This will cause damage to your battery. The biggest tell that your battery
needs more electrolytes is if the plates are exposed or almost exposed and if the
electrolytes aren’t equal in each cell.

 Add Distilled Water 

Beyond the apparent solution of keeping the battery charged by running the engine, the
only direct way to increase electrolytes in your car battery is to add distilled water. Also,
if your battery is already low, filling it with distilled water before charging will help
reduce gas accumulation.  Add enough distilled water to cover the plates or electrodes.
Adding too much water can be dangerous for the battery. If your battery is still relatively
new and well charged, you can add just enough distilled water to meet the bottom of the
filler tube. Please note that electrolytes strictly mean distilled water and not any other
water or acid. 
  Keep the Battery Secure 

Keeping your battery secure is an essential car battery maintenance tip and also helps to
prevent damage to your car parts. For example, a loose battery can vibrate, resulting in
short circuits. Besides, it can also tip over and bash against other parts of your engine in
transit. This can cause battery acid to spill all over your motor. It’s best to ensure your
battery sits correctly and is secured tightly, especially if you drive on a bumpy road. 

 Clean Your Battery

Cleaning your battery on a regular basis is the most critical part of maintaining your car
battery. If your battery constantly has grime or dirt on its surface, the battery casing may
leak, leading to a short circuit. Also, a dirty battery connection can weaken the charge.

7.1.2 How to Know Your Battery is Bad?

While car battery maintenance is essential, there are times when the battery may become
faulty. Recognizing the signs instantly and taking it in for repair will save you money and
energy. Here are a few signs of a bad battery: 

 Slow Engine

If your engine takes time to start, or it doesn’t warm up quickly enough, or as easy as it
used to, you probably have a bad battery. 
  Bad Lights 

The battery powers the electrical circuits and the headlights, dashboard lights, and
interior cabin lights. So, if the lights in your car suddenly start to go off one by one or
start to flicker or dim, you need to check your battery. 

 Cranking Sounds

If your car battery is starting to rust, it is likely to produce a cranking sound when you are
driving. A rusted car battery is bad for the car’s functionality and it can also be dangerous
to other car parts under the hood. 

 Poor Ignition 

If it takes time for your car to start after ignition, or if it flickers a few times before power
gets to your engine, your battery is probably going bad. In the worst case, the car will
produce a poor ticking ignition sound when you turn the key but won’t start. You may
need a total battery replacement to fix things in any such case. 

So charging is necessary
Follow the instructions for your particular charger. Basic instructions for most chargers
include:

 
 Make sure the charger is off.
 Hook-up the positive cable on the charger to the positive terminal on the battery.
 Hook up the negative cable on the charger to the negative terminal on the battery.
 Set the charger to the slowest charge rate.
 Turn on the charger and set the timer.
 will take about 60% of the total charging time to charge a lead acid battery to 80%, and
the remaining 40% of the time to put the last 20% of charge back into the battery.

The recharging duration is difficult to determine due to variables such as:

Ÿ Depth of discharge

Ÿ Temperature

Ÿ Size and efficiency of the charger

Age and condition of the battery

Connecting Batteries - Parallel Connection

Ÿ When connecting multiple 12 volt batteries in parallel, you are increasing the capacity of
the battery bank while maintaining the voltage. E.g. 3 x 12 volt 60Ah batteries when
parallel connected will create a 12 volt 180Ah bank.
Ÿ When connected to a battery charger, the charging current is divided between all the
batteries in the bank. E.g. A 15-amp charger connected to 3 batteries will provide up to 5
amps current into each battery.

Connecting Batteries - Series Connection