MANUFACTURING
Jolson Technologies has experience in lead-acid battery manufacturing. Dr. Olson worked for Optima Batteries from 1994 to 2001 and was involved in plant operation and troubleshooting. As R&D Manager he oversaw operations of the prototype lab, chemistry lab and the test lab. We can provide service in areas of process troubleshooting, testing audits, quality audits or design review. An outside pair of eyes is often helpful to uncover issues that are difficult for the production team to resolve. In addition, manufacturing is geared to productivity and internal improvement projects may lack adequate resources. We can also work with your suppliers or customers to identify and solve problems.
As discussed in our description of our areas of expertise, our capabilities lie in the realm of materials and performance. We understand the chemical side of battery manufacturing. Often lapses in product quality can be found in changes in materials or processes that change the materials chemistry.
Cost reduction: Cost reduction projects are often materials focused. Can we change to a lower cost supplier and not impact product quality?
Audits: Are we currently meeting our specifications? Do our specifications need to be changed? Are our quality procedures adequate to ensure product quality, or perhaps are they excessive? An independent eye can often see issues that are overlooked by technical staff?
Troubleshooting: Battery quality issues can be very expensive (increased scrap) and urgent. Quite often they can involve chemistry related issues with incoming materials or processes. We have the technical capabilities to integrate with your team to identify and solve quality problems.
CHARGING
Dr. Olson has particular expertise in charging lead-acid batteries. In particular, sealed (aka VRLA, AGM, Gel) batteries are difficult to charge properly. Overcharge leads to dramatic lower lifetimes, but undercharge is worse leading to a rapid loss of capacity. To make things more complex, the optimum charge varies over the life of the battery. Charging large packs adds another layer of complexity to the optimization of charging.
Long Charge Times: Any lead-acid battery requires long charge times of about 16 hours for full charge. Dr. Olson has developed effective charge algorithms that can reduce this time to 3 – 4 hours.
Recovering Aged Batteries: Another important area is recovering aged batteries. Lead-acid batteries will become resistant to standard charging techniques if they have aged due to prolonged storage. These batteries develop ‘sulfation’ which is resistant to charging. Depending on the condition of the battery they may be permanently damaged or can be recovered with aggressive charging techniques.
Thermal Runaway: A related topic for sealed lead-acid batteries is thermal runaway. Overcharging, particularly at higher temperatures, can lead to thermal runaway that can permanently damage the batteries. Dr. Olson understands the mechanisms and can help you avoid the dangers of thermal runaway.