Abstract: A device, configured as a double mold, for casting terminal bars (straps) and terminal poles onto the lugs of a completely assembled plate group for electric storage batteries ensures optimum attachment of all of the lugs (both polarities) to the molten bar lead if the heat exchange between the bar lead and the dipped volume of each negative or positive lug is identical. This requirement is met by causing the negative and positive casting molds, together with their contents, to form thermally equivalent sections or blocks, which are equalized if necessary, by changing the dimensions (thickness) of the mold's walls. When the lugs are made of lead or a lead alloy, such a double mold also makes it possible, during a subsequent two-stage cooling process, to first allow the terminal poles to solidify, simultaneously, and to then allow the terminal bars to solidify, simultaneously.

Abstract: A method and apparatus for casting straps onto the plate lugs of battery cell elements. The apparatus includes a rotatably indexable table having a plurality of mold and element carrying stations which each are successively indexed through a plurality of operating stations, including an element loading station, an element lug alignment station, a molten-metal pouring station, a lug fluxing station, a casting station, a plurality of mold cooling stations, and an element unloading station. The mold of each table station is adapted for efficient and precisely controlled electrical resistance heating and forced-air cooling during each cycle of operation. In the illustrated embodiment, each table-station mold is successively heated from electrical sources at a plurality of operating stations upon indexing of the respective table station to such operating stations and is cooled by directing air through air-direction tubes mounted on each table station in close proximity to the respective mold.

Abstract: In the method of the invention a laminated rotor is made using four different types of laminae, to form a stack of laminae into which molten conductor metal is poured to form cast conductors through aligned conductor slots in each of the laminae while transition laminae function to prevent the flow of metal into the coolant ducts of the stacked assembly. Practice of the method of the invention provides for making a plurality of laminated rotor assemblies, all of which utilize standard duct laminae configurations, but some of which have different configurations of conductor slots in either or both the main rotor laminae and the vent laminae used therein. In the method of the invention standardized sets of duct laminae are used in making a plurality of different rotor assemblies, which have, respectively, different sizes and shapes of conductor slots through the main rotor and/or vent laminae thereof.

Abstract: Ultrasonically joining a plurality of discrete lead parts into a shaped, substantially metallurgically homogeneous joint. Preshaped lead pieces are placed in an ultrasonically vibrated mold for fusing the pieces and shaping the joint. The method is exemplified in the making of terminal posts for Pb-acid storage batteries.

Abstract: A method for the die casting of end rings and conductor bars in rotors employing a die casting machine having a compensator mechanism comprising a compensator sleeve and a compensator for reciprocal movement along a first axis. A coaxially movable die plate closes off one end of the compensator sleeve to form a die cavity for casting. A plurality of lamination stacks, each held together by a removable stacking pin, are stored on an inclined loading rack positioned laterally on one side of the compensator mechanism. A few of these stacks roll down inclined planes into the compensator sleeves. The compensator pushes the stacks forward into abutment with the die plate and a charge of molten material is injected into the die cavity. The die plate then moves axially away from the compensator and a retriever moves perpendicular to the first axis to an unload position between the compensator sleeve and die plate.

Abstract: Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case. Molding channels are automatically formed around the positive and negative rows of lugs and molten lead alloy is automatically introduced into the molding channels to cast the straps and intercell connections simultaneously within the battery case.

Abstract: Method of connecting a battery plate to a battery strap or post in a mould 50 provided with a number of separate mould cavities 51 arranged on each side of a duct or channel 52 for receiving molten lead. Between each mould cavity 51 and the channel 52 is positioned a weir or barrier 60 which determines the level of lead in each cavity. Lead pumped into the channel 52 flows into the cavities 51 over the weirs 60, the level of lead in channel 52 then drops below the top of the weirs 60 so that the level of lead in the cavities 51 falls to the level of the top of the weirs 60. The lugs 22 of battery plates 23 are then dipped into the lead in the cavities and the lead solidifies to form finished straps or posts. During the moulding process the lead is maintained in a molten state using heaters 78 and the mould cavities are cooled with a flow of cooling water.

Abstract: An automatic part loading unit for loading various diameter and stack height sizes of rotor assemblies into the compensator sleeves of multiple cavity rotor dies for the subsequent casting of the conductor bars and end rings of squirrel cage electrical motor rotors. The loading unit comprises a magazine section having a plurality of inclined guide tracks on which the rotor preforms are stacked, and an escapement mechanism which permits one rotor preform at a time to roll from each of the guide tracks in the magazine section onto respective inclined guide tracks leading to the breech openings of the die cavities. The guide tracks are laterally adjustable so as to accommodate rotor preforms of various stack height. As the rotor preforms roll down the inclined guide track toward the die cavities, they are decelerated by means of pivotally mounted, counterweighted arms which are contacted by and then swung out of the way by the rotors.

Abstract: A novel "cast-on" method and apparatus are disclosed wherein in the preferred embodiment only one major moving part is provided which is indexed through various positions to cast a group or element from a battery plate stack engaged thereby. In the preferred embodiment, a mold carriage block having a plurality of mold voids formed therethrough slidingly reciprocates along a base plate on which are defined fluxing (loading), casting and part-release positions. In the casting position, lead gravitationally siphons into the mold voids defined in the mold carriage through molten lead supply orifices defined in the base plate along which the carriage slides. Once the casting operation is completed, sliding the carriage out of the casting position effectively seals the molten lead supply orifices. The apparatus and method are particularly suited for use by a single operater who manually loads stacks into the apparatus and subsequently unloads completed groups or elements from the apparatus.

Abstract: A novel "cast-on" method and apparatus are disclosed wherein in the preferred embodiment only one major moving part is provided which is indexed through various positions to cast a group or element from a battery plate stack engaged thereby. In the preferred embodiment, a mold carriage block having a plurality of mold voids formed therethrough slidingly reciprocates along a base plate on which are defined fluxing (loading), casting and part-release positions. In the casting position, lead gravitationally siphons into the mold voids defined in the mold carriage through molten lead supply orifices defined in the base plate along which the carriage slides. Once the casting operation is completed, sliding the carriage out of the casting position effectively seals the molten lead supply orifices. The apparatus and method are particularly suited for use by a single operator who manually loads stacks into the apparatus and subsequently unloads completed groups or elements from the apparatus.

Abstract: For inclusion as spacer between first and second axially spaced apart members mounted for limited angulation about a common axis, the first member having a seal recess formed in one face, the second member having an end face opposite the seal recess, the improvement of: a laminated torsielastic bushing arranged in one piece, and in the recess.

Abstract: An improvement in the process and apparatus for converting molten metal, especially steel, into a finished product by first converting the molten metal into thin layers which are superimposed on one another while hot and pressure welding the layers into a unitary body that is particularly adapted for hot or cold shaping into a final size and shape, with the advantage of accelerating the cooling of the molten metal and obtaining the improved grain structure and more nearly uniform distribution of alloying ingredients obtainable from rapid solidification of the molten steel to a solid, comprises forming several separate layers from a common heat of molten metal, simultaneously or successively pressure welding utilizing the layers into a unitary body in a single pressure welding station, in contrast to methods of and apparatus for producing a product from several layers requiring a separate casting unit for each separate layer or thickness and also requiring a pair of pressure rolls for each separate added layer

Abstract: A preferred process includes arranging field yoke segments, pole face segments, and one or more pieces of ceramic magnet material so that the yoke segments and pole face segments can be relied upon to establish low reluctance paths for magnetic flux associated with the ceramic magnet material. The process includes holding the ceramic magnet material sandwiched between the yoke pieces and pole pieces within a cavity of a casting fixture; admitting a molten metallic material to the cavity and adjacent to the yoke, pole, and ceramic material pieces; permitting the molten material to solidify; and thereafter removing the field assembly from the cavity with the ceramic pieces completely surrounded and encased by the pole pieces, yoke pieces, and solidified material. In a more preferred form, molten aluminum at a temperature of at least about 660.degree. C is used as the molten metallic material even though the resulting thermal shock causes a fracturing or shattering of the ceramic material.

Abstract: An improved piston construction comprising a piston body having a crown and a depending skirt, a peripheral groove about the body intermediate the crown and the skirt closely adjacent the crown, a grooved insert band in the groove and adapted to receive at least one piston ring, and at least one frustoconical washer in the groove abutting the insert band on the side thereof closest the crown, the washer having its minor base directed toward the skirt and its major base directed toward the crown and being stressed into a substantially planar configuration to store energy to tightly clamp the insert band within the groove to preclude loosening of the band during operation of an engine employing the piston. Also disclosed is a method of fabricating the improved piston construction.

Abstract: A novel system for assembling industrial or motive power batteries is described which basically comprises a conveyor surface, a plurality of stacking box means freely movable across said conveyor surface, tilt table means for engaging in tilting said stacking box, and a novel burning apparatus for forming battery straps on any of a plurality of different sized battery stacks formed within said stacking box means. Additionally, a novel automated burning apparatus is provided wherein a plurality of torches are adapted for a square movement across the terminal lugs of the battery stack, thereby facilitating the formation of battery straps and terminal posts on each of a plurality of battery stacks during a single operation. Utilization of the present system facilitates the efficient manufacture of industrial or motive power batteries of any of a number of different sizes.

Abstract: Die casting apparatus for casting parts such as rotors or the like comprises a three tie bar horizontally disposed die casting machine, with an indexing mechanism mounted on one of the tie bars for rotating the parts through six separate radially spaced work stations. The work stations include loading, casting, cooling, skew pin ejection, and unloading stations. The casting station includes a four plate die assembly comprising a runner plate, cover die, carrier plate, and ejector die. The die assembly employs pin-point gating and is formed such that the cast part is removed from the die and the runner system, and the runner system is ejected from the apparatus, while the part is at the casting station. A movable runner ejector plate having ejector pins ejects the runner from the runner plate. A compensating cylinder is provided for adjustment for variance in stack height.