The Automobile Storage Battery Part 1

The Automobile Storage Battery.

by O. A. Witte.

Preface

Many books have been written on Storage Batteries used in stationary work, as in electric power stations. The storage battery, as used on the modern gasoline car, however, is subjected to service which is radically different from that of the battery in stationary work. It is true that the chemical actions are the same in all lead-acid storage batteries, but the design, construction, and operation of the starting and lighting battery, the radio battery, and the farm lighting battery are unique, and require a special description.

Many books have been written on Storage Batteries used in stationary work, as in electric power stations. The storage battery, as used on the modern gasoline car, however, is subjected to service which is radically different from that of the battery in stationary work. It is true that the chemical actions are the same in all lead-acid storage batteries, but the design, construction, and operation of the starting and lighting battery, the radio battery, and the farm lighting battery are unique, and require a special description.

This book therefore refers only to the lead-acid type of starting and lighting battery used on the modern gasoline Automobile, the batteries used with Radio sets, and the batteries used with Farm Lighting Plants. It is divided into two sections. The first section covers the theory, design, operating conditions, and care of the battery.

The second section will be especially valuable to the battery repairman. All the instructions given have been in actual use for years, and represent the acc.u.mulated experiences of the most up-to-date battery repair shops in the United States.

The first edition of this book met with a most pleasing reception from both repairmen and battery manufacturers. It was written to fill the need for a complete treatise on the Automobile Storage Battery for the use of battery repairmen. The rapid sale of the book, and the letters of appreciation from those who read it, proved that such a need existed.

The automobile battery business is a growing one, and one in which new designs and processes are continually developed, and in preparing the second and third editions, this has been kept in mind. Some of the chapters have been entirely rewritten, and new chapters have been added to bring the text up-to-date. Old methods have been discarded, and new ones described. A section on Farm lighting Batteries has been added, as the automobile battery man should familiarize himself with such batteries, and be able to repair them. A section on Radio batteries has also been added.

Special thanks are due those who offered their cooperation in the preparation and revision of the book. Mr. George M. Howard of the Electric Storage Battery Co., and Mr. C. L. Merrill of the U. S. Light & Heat Corporation very kindly gave many helpful suggestions. They also prepared special articles which have been incorporated in the book. Mr. Henry E. Peers consulted with the author and gave much valuable a.s.sistance. Mr. Lawrence Pearson of the Philadelphia Battery Co., Mr. F. S. Armstrong of the Vesta Acc.u.mulator Co., Messrs. P. L.

Rittenhouse, E. C. Hicks and W. C. Brooks of the Prest-O-Lite Co., Mr.

D. M. Simpson of the General Lead Batteries Co., Mr. R. D. Mowray and Mr. C. R. Story of the Universal Battery Co., Mr. H. A. Harvey of the U. S. Light and Heat Corporation, Mr. E. B. Welsh of the Westinghouse Union Battery Co., Mr. S. E. Baldwin of the Willard Storage Battery Co., Mr. H. H. Ketcham of the United Y. M. C. A. Schools, and Messrs.

Guttenberger and Steger of the American Eveready Works also rendered much valuable a.s.sistance.

The Chapter on Business Methods was prepared by Mr. G. W. Hafner.

O. A. WITTE, Chief Engineer, American Bureau of Engineering, Inc.

September, 1922

Section I

Working Principles, Manufacture, Maintenance, Diseases, and Remedies

The Automobile Storage Battery

CHAPTER 1.

INTRODUCTORY.

Gasoline and electricity have made possible the modern automobile.

Each has its work to do in the operation of the car, and if either fails to perform its duties, the car cannot move. The action of the gasoline, and the mechanisms that control it are comparatively simple, and easily understood, because gasoline is something definite which we can see and feel, and which can be weighed, or measured in gallons.

Electricity, on the other hand, is invisible, cannot be poured into cans or tanks, has no odor, and, therefore, n.o.body knows just what it is. We can only study the effects of electricity, and the wires, coils, and similar apparatus in which it is present. It is for this reason that an air of mystery surrounds electrical things, especially to the man who has not made a special study of the subject.

Without electricity, there would be no gasoline engine, because gasoline itself cannot cause the engine to operate. It is only when the electrical spark explodes or "ignites" the mixture of gasoline and air which has been drawn into the engine cylinders that the engine develops power. Thus an electrical ignition system has always been an essential part of every gasoline automobile.

The first step in the use of electricity on the automobile, in addition to the ignition system, consisted in the installation of an electric lighting system to replace the inconvenient oil or gas lamps which were satisfactory as far as the light they gave was concerned, but which had the disadvantage of requiring the driver to leave his seat, and light each lamp separately, often in a strong wind or rain which consumed many matches, time, and frequently spoiled his temper for the remainder of the evening. Electric lamps have none of these disadvantages. They can be controlled from the driver's seat, can be turned on or off by merely turning or pushing a switch-b.u.t.ton, are not affected by wind or rain, do not smoke up the lenses, and do not send a stream of unpleasant odors back to the pa.s.sengers.

The apparatus used to supply the electricity for the lamps consisted of a generator, or a "storage" battery, or both. The generator alone had the disadvantage that the lamps could be used only while the engine was running. The battery, on the other hand, furnished light at all times, but had to be removed from the car frequently, and "charged." With both the generator and battery, the lights could be turned on whether the engine was running or not, and, furthermore, it was no longer necessary to remove the battery to "charge," or put new life into it. With a generator and storage battery, moreover, a reliable source of electricity for ignition was provided, and so we find dry batteries and magnetos being discarded in a great many automobiles and "battery ignition" systems subst.i.tuted.

The development of electric lighting systems increased the popularity of the automobile, but the motor car still had a great drawback-cranking. Owing to the peculiar features of a gasoline engine, it must first be put in motion by some external power before it will begin to operate under its own power. This made it necessary for the driver to "crank" the engine, or start it moving, by means of a handle attached to the engine shaft. Cranking a large engine is difficult, especially if it is cold, and often results in tired muscles, and soiled clothes and tempers. It also made it impossible for the average woman to drive a car because she did not have the strength necessary to "crank" an engine.

The next step in the perfection of the automobile was naturally the development of an automatic device to crank the engine, and thus make the driving of a car a pleasure rather than a task. We find, therefore, that in 1912, "self-starters" began to be used. These were not all electrical, some used tanks of compressed air, others acetylene, and various mechanical devices, such as the spring starters. The electrical starters, however, proved their superiority immediately, and filled such a long felt want that all the various makes of automobiles now have electric starters. The present day motor car, therefore, uses gasoline for the engine only, but uses electricity for ignition, starting, lighting, for the horn, cigar lighters, hand warmers on the steering wheel, gasoline vaporizers, and even for shifting speed changing gears, and for the brakes.

On any car that uses an electric lighting and starting system, there are two sources of electricity, the generator and the battery, These must furnish the power for the starting, or "cranking" motor, the ignition, the lights, the horn, and the other devices. The demands made upon the generator are comparatively light and simple, and no severe work is done by it. The battery, on the other hand is called upon to give a much more severe service, that of furnishing the power to crank the engine. It must also perform all the duties of the generator when the engine is not running, since a generator must be in motion in order to produce electricity.

A generator is made of iron, copper, carbon, and insulation. These are all solid substances which can easily be built in any size or shape, and which undergo very little change as parts of the generator. The battery is made mainly of lead, lead compounds, water and sulphuric acid. Here we have liquids as well as solids, which produce electricity by changes in their composition, resulting in complicated chemical as well as electrical actions.

[Fig. 1 The Battery]

The battery is, because of its construction and performance, a much abused, neglected piece of apparatus which is but partly understood, even by many electrical experts, for to understand it thoroughly requires a study of chemistry as well as of electricity. Knowledge of the construction and action of a storage battery is not enough to make anyone an expert battery man. He must also know how to regulate the operating conditions so as to obtain the best service from the battery, and he must be able to make complete repairs on any battery no matter what its condition may be.

CHAPTER 2.

BATTERIES IN GENERAL

There are two ways of "generating" electricity on the car: 1.

Magnetically, 2. Chemically. The first method is that used in a generator, in which wires are rotated in a "field" in which magnetic forces act. The second method is that of the battery, and the one in which we are now interested.

If two unlike metals or conducting substances are placed in a liquid which causes a greater chemical change in one of the substances than in the other, an electrical pressure, or "electromotive" force is caused to exist between the two metals or conducting substances. The greater the difference in the chemical action on the substances, the greater will be the electrical pressure, and if the substances are connected together outside of the liquid by a wire or other conductor of electricity, an electric current will flow through the path or "circuit" consisting of the liquid, the two substances which are immersed in the liquid, and the external wire or conductor.

As the current flows through the combination of the liquid, and the substances immersed in it, which is called a voltaic "cell," one or both of the substances undergo chemical changes which continue until one of the substances is entirely changed. These chemical changes produce the electrical pressure which causes the current to flow, and the flow will continue until one or both of the substances are changed entirely. This change due to the chemical action may result in the formation of gases, or of solid compounds. If gases are formed they escape and are lost. If solids are formed, no material is actually lost.

a.s.suming that one of the conducting substances, or "electrodes," which are immersed in the liquid has been acted upon by the liquid, or "electrolyte," until no further chemical action can take place, our voltaic cell will no longer be capable of causing a flow of electricity. If none of the substances resulting from the original chemical action have been lost as gases, it may be possible to reverse the entire set of operations which have taken place. That is, suppose we now send a current through the cell from an outside source of electricity, in a direction opposite to that in which the current produced by the chemical action between the electrodes and electrolyte flowed. If this current now produces chemical actions between electrodes and electrolyte which are the reverse of those which occurred originally, so that finally we have the electrodes and electrolyte brought back to their original composition and condition, we have the cell just as it was before we used it for the production of an electrical pressure. The cell can now again be used as a source of electricity as long as the electrolyte acts upon the electrodes, or until it is "discharged" and incapable of any further production of electrical pressure. Sending a current through a discharged cell, so as to reverse the chemical actions which brought about the discharged conditions, is called "charging" the cell.

[Fig. 2 A complete cell; Negative group; Positive group]

Cells in which an electrical pressure is produced as soon as the electrodes are immersed in the electrolyte are called it "primary"

Cells. In these cells it is often impossible, and always unsatisfactory to reverse the chemical action as explained above.

Cells whose chemical actions are reversible are called "storage" or "secondary" cells. In the "storage" cells used today, a current must first be sent through the cell in order to cause the chemical changes which result in putting the electrodes and electrolyte, in such a condition that they will be capable of producing an electrical pressure when the chemical changes caused by the current are complete.

The cell now possesses all the characteristics of a primary cell, and may be used as a source of electricity until "discharged." It may then be "charged" again, and so on, the chemical action in one case causing a flow of current, and a reversed flow of current causing reversed chemical actions.

We see from the above that the "storage" battery does not "store"

electricity at all, but changes chemical into electrical energy when "discharging," and changes electrical into chemical energy when "charging," the two actions being entirely reversible. The idea of "storing" electricity comes from the fact that if we send a current of electricity through the cell for a certain length of time, we can at a later time draw a current from the cell for almost the same length of time.

[Fig. 3 Complete Element]

Fig. 3. A complete element, consisting of a positive and negative group of plates and separators ready for placing in the hard rubber jars.

Three things are therefore required in a storage cell, the liquid or "electrolyte" and two unlike substances or electrodes, through which a current of electricity can pa.s.s and which are acted upon by the electrolyte with a chemical action that is greater for one substance than the other. In the storage cell used on the automobile today for starting and lighting, the electrodes are lead and peroxide of lead, and the electrolyte is a mixture of sulphuric acid and water. The peroxide of lead electrode is the one upon which the electrolyte has the greater chemical effect, and it is called the positive or "+"

electrode, because when the battery is sending a. current through an external circuit, the current flows from this electrode through the external circuit, and back to the lead electrode, which is called the negative, or electrode.