Structure and Discharge Process of Diesel Generator Batteries

Diesel generators rely on batteries for crucial functions like starting the engine, yet many users lack a comprehensive understanding of their components and discharge mechanisms. To help you gain a clearer grasp of this essential component, Dingbo Diesel Generator Manufacturer is providing a detailed breakdown of diesel generator battery structures and the science behind their discharge process.

1.Components of a Diesel Generator Battery

Supports: These components play a critical role in preventing the battery plates from bending or deforming during operation, ensuring the structural integrity of the battery and maintaining consistent performance over time.

Connectors: Connectors serve to link plates of the same polarity within a single battery to form a plate group, facilitating efficient electrical conductivity. Inter-battery connections can be made using external connection bars mounted on top of the battery covers or through a through-wall internal connection method, both designed to ensure stable and low-resistance current transfer between individual battery units.

Insulators: When installing and securing lead-acid battery banks, insulators are essential to prevent electrical leakage. Glass or porcelain insulating feet must be placed between the batteries and their wooden mounting frames, as well as between the wooden frames and the ground. Soft rubber gaskets are also added to enhance stability. To maintain effective insulation and prevent leakage, these insulating components should be cleaned regularly to remove any accumulated acid residue or dust, which could compromise their insulating properties and lead to battery malfunction.

2.Explanation of the Lead-Acid Battery Discharge Process

When a lead-acid battery is connected to a load, current flows through the external circuit, triggering a series of electrochemical reactions at both electrodes. The key reactions occurring during the discharge process are as follows:

Negative Electrode Reaction: Pb - 2e⁻ + SO₄²⁻ → PbSO₄

Positive Electrode Reaction: PbO₂ + SO₄²⁻ + 4H⁺ + 2e⁻ → PbSO₄ + 2H₂O

Overall Battery Reaction: Pb + 4H⁺ + 2SO₄²⁻ + PbO₂ → 2PbSO₄ + 2H₂O, or alternatively expressed as: Pb + 2H₂SO₄ + PbO₂ → 2PbSO₄ + 2H₂O

From the overall battery reaction, it is evident that lead sulfate (PbSO₄) is formed at both electrodes during discharge. As the discharge process continues, sulfuric acid in the electrolyte is gradually consumed, while water is produced, resulting in a decrease in the electrolyte's concentration (density). Therefore, the density of the electrolyte serves as a reliable indicator of the battery's discharge level. For flooded lead-acid batteries, electrolyte density is commonly used to determine the end of the discharge cycle. Typically, when the electrolyte density drops to approximately 1.15–1.17 kg/L, discharge should be immediately stopped. Continuing to discharge beyond this point can cause irreversible damage to the battery due to over-discharging, significantly shortening its service life.

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