Abstract: A punch head comprises a low profile hydraulic anvil piston with a punch across from a die on opposite sides of a gap between two legs. One of the legs comprises a position sensor disposed on the bottom of the leg. For example, a plurality of punch heads are disposed on a jig or frame and are positioned using one or more of the position sensors. For example, the position sensor is a mini fiber optic position sensor mounted in a recessed portion at the bottom of one or more of the punch heads.

Abstract: A die casting machine has a carousel and a plurality of molds disposed around the carousel. The carousel rotates about a central axis, such that each of the plurality of molds comes into a position for casting in turn. Each mold has a toggle mechanism and extraction pins. A gripping mechanism may extend up through a hole in the carousel table to couple the toggle mechanism to an actuator. At least one of the pins may have a pin brake such that the pins remain in position when the mold is opened, suspending a newly cast metal part in mid-air, when the brake is activated. When the brake is deactivated, the pins may retract, and the part may be removed without damaging the cast part.

Abstract: A soldering jig comprises a shaped hole that fits a corresponding battery terminal, such as a square battery terminal, and provides a cavity for insertion of a solder wire. An opposite side from the cavity for insertion of the solder wire provides a blind hole for insertion of one end of the solder wire and a template for bending and cutting the solder wire to a correct length. Once cut, the solder wire is inserted into the cavity and is resiliently retained until the solder wire and jig are inverted and placed onto a hot battery terminal. Under pressure and residual heat the hot battery terminal, the solder wire melts, soldering an interface.

Abstract: The invention relates to an improved apparatus and method for assembling a battery. The invention includes an improved apparatus and method for sealing a battery case closure to a battery case. The apparatus comprises a device for moving a carrier with fluid pressure through fluid conduits disposed internal a shaft. A novel case stop is disclosed for stopping and positioning a battery case on a support. A method is disclosed for heating a battery case with a case heater. A conveyor system is included for sequentially moving a plurality of flat battery components such as case closures.

Abstract: A conveyor system is disclosed for sequentially moving a plurality of flat battery components. The conveyor has a plurality of separators for receiving a flat battery component between each of the adjacent separators. The conveyor supports an end of each flat battery component with each of the flat battery components being maintained on end by the plurality of separators. A motor drive is provided for moving the conveyor for moving the plurality of flat battery components.

Abstract: An improved bushing mold is disclosed for an apparatus for welding a battery terminal post to a battery bushing. The battery terminal post is electrically connected to a battery plate disposed within a battery case and the battery bushing is secured to a battery case cover with the bushing having a central bushing aperture for receiving the battery terminal post therein when the battery case cover is located on the battery case. The bushing mold comprises an electrically conductive mold body having an insulating mold insert. The mold insert comprises a first and a second insert portion with the second insert portion being replaceable independent of the first insert portion.

Abstract: The method of heating a battery case with a case heater is disclosed comprising the steps of rapidly moving the case heater into engagement with the battery case. After engagement of the case heater with the battery case, the case heater is slowly moved a predetermined distance to melt the battery case.

Abstract: The invention relates to an improved apparatus and method for assembling a battery. The invention includes an improved apparatus and method for sealing a battery case closure to a battery case. The apparatus comprises a device for moving a carrier with fluid pressure through fluid conduits disposed internal a shaft. A novel case stop is disclosed for stopping and positioning a battery case on a support. A method is disclosed for heating a battery case with a case heater. A conveyor system is included for sequentially moving a plurality of flat battery components such as case closures.

Abstract: The invention relates to an improved apparatus and method for assembling a battery. The invention includes an improved apparatus and method for sealing a battery case closure to a battery case. The apparatus comprises a device for moving a carrier with fluid pressure through fluid conduits disposed internal a shaft. A novel case stop is disclosed for stopping and positioning a battery case on a support. A method is disclosed for heating a battery case with a case heater. A conveyor system is included for sequentially moving a plurality of flat battery components such as case closures.

Abstract: An improved control system for a movement actuator is disclosed for moving a member between a retracted position and an extended position. The movement actuator comprises a cylinder having a piston with a fluid supply providing pressure to a first and a second side of the piston. A control applies a first and a second fluid pressure on the first and second sides of the piston for moving the member from the retracted position toward the extended position with a force related to a difference between the first fluid pressure and second fluid pressure for reducing the possibility of damage to an unintended object in the path of the member. The control applies the first fluid pressure on the first side of the piston upon the member being in proximity to the extended position for moving the member into the extended position with a force related to the first fluid pressure for insuring proper positioning of the member.

Abstract: An improved resistive electrode is disclosed for a welding apparatus for welding a battery terminal post to a battery bushing, The battery terminal post is electrically connected to a battery plate disposed within a battery case and the battery bushing is secured to a battery case cover with the bushing having a central bushing aperture for receiving the battery terminal post therein when the battery case cover is located on the battery case. The resistive electrode comprising a resistive electrode extending between a base end and a tip end with the base end being secured to a power source. A conductive member engages the resistive electrode for facilitating the flow of electric power from the base end to the tip end for concentrating the resistive heat proximate to the tip end of the resistive electrode.

Abstract: A bottom gating mold system which is particularly adapted for molding relatively flat and generally elongated and/or wide metal objects such as battery plates or grids.