Note: Melting lead ingots to form battery posts and connectors

Objective:

Melting 30 lb (13.6 kg) & 60 lb (27.2 kg) lead ingots to form battery posts & connectors 

End Product:

Battery terminals

Equipment:

Ambrell 50 kW induction heating system, equipped with a remote workhead containing three 26μF capacitors for a total of 80μF
An induction heating coil designed and developed specifically for this application.

Materials:

30 lb (13.6 kg) & 60 lb (27.2 kg) lead ingots 5 in (12.7 cm) ID Zircar Ceramic Alumina tube

Temperature:

620 °F

Frequency:

10 kHz

Testing:

A five turn helical coil is used for this application. Lead ingots are placed inside the ceramic tube which is inside the coil. Different size ingots are melted at specified power, voltage and frequencies, see table below. As the lead melts and flows out of the tube the coil coupling decreases, a constant feed of lead is required for a consistent flow and coil coupling. 
melting_08 chart

Benefits:

  • Faster startup/shutdown time saves energy

  • Cleaner process than furnace melting

  • Safer and more cost effective

  • Hands-free heating that involves no operator skill for manufacturing

  • Even distribution of heating 

Melting lead ingots to form battery posts and connectors

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