Apparatus and method for cold forming a ring on a lead alloy battery terminal including an anti-torque structure

An apparatus for forming rings on a battery terminal without substantially removing material from the battery terminal, the apparatus comprising:

• a station configured to securely position the battery terminal within a fixture;
• a rolling station including a cold metal forming member configured to form rings on the outer surface of the battery terminal when the terminal and cold metal forming member are rotated relative to each other;
• and
• a drive assembly configured to rotate the terminal and cold metal forming member relative to each other.

An apparatus for forming rings on a lead battery terminal, the apparatus comprising:

• a seating station configured to securely position the battery terminal within a fixture;
• a rolling station including a ring forming head configured to form rings on the lead battery terminal when the terminal and ring forming head are rotated relative to each other;
• and
• a drive assembly fastened to the fixture and head to rotate the terminal and ring forming head relative to each other,
• the fixture including a die having a recess configured to receive the battery terminal, and at least one projection located proximate the recess configured to engage the battery terminal to prevent rotation of the battery terminal within the die, wherein the seating station includes a moveable seating punch located above the fixture to engage the battery terminal with the at least one projection.

An apparatus for forming rings on a lead battery terminal, the apparatus comprising:

• a seating station configured to securely position the battery terminal within a fixture;
• a rolling station including a ring forming head configured to form rings on the lead battery terminal when the terminal and ring forming head are rotated relative to each other;
• and
• a drive assembly fastened to the fixture and head to rotate the terminal and ring forming head relative to each other,
• the fixture including a die having a recess configured to receive the battery terminal, and at least one projection located proximate the recess configured to engage the battery terminal to prevent rotation of the battery terminal within the die,
• the die including a top surface, and a radial surface located within the recess a set distance from the top surface, the at least one projection extending from the radial surface toward the top surface, wherein the die includes a plurality of projections extending from the radial surface toward the top surface.

An apparatus for forming rings on a lead battery terminal, the apparatus comprising:

• a seating station configured to securely position the battery terminal within a fixture;
• a rolling station including a ring forming head configured to form rings on the lead battery terminal when the terminal and ring forming head are rotated relative to each other;
• and
• a drive assembly fastened to the fixture and head to rotate the terminal and ring forming head relative to each other, wherein the ring forming head includes a plurality of rollers each having a flat portion, wherein the rollers are configured to form a ring on the lead battery terminal.

A method for forming a ring on a lead battery terminal, the method comprising the steps of:

• securing the lead battery terminal within a fixture;
• engaging a cold metal forming member with the outer surface of the lead battery terminal while the cold metal forming member and the lead battery terminal are rotating relative to each other;
• and
• forming a ring on the lead battery terminal, without substantially removing any material.

A method for forming a ring on a lead battery terminal, the method comprising the steps of:

• securing the lead battery terminal within a fixture:
• and
• engaging a ring forming head with the lead battery terminal while the rolling head and the lead battery terminal are rotating relative to each other,
• the step of securing includes seating the battery terminal within a die located within the fixture,
• wherein the step of seating includes forming at least one depression on the battery terminal on a projection located in the die.

A method for forming a ring on a lead battery terminal, the method comprising the steps of:

• securing the lead battery terminal within a fixture;
• and
• engaging a ring forming head with the lead battery terminal while the rolling head and the lead battery terminal are rotating relative to each other,
• the step of securing includes seating the battery terminal within a die located within the fixture, wherein the step of seating includes forming a plurality of depressions on the battery terminal on a plurality of projections located in the die.