REDARTI Multi-Channel Battery Formation (Initial Charge) Rectifiers are our most advanced industrial power systems and our company's flagship, enabling the electrochemical activation of plates and raw batteries produced in the battery manufacturing industry. Formation — the most critical stage of battery production — requires the initial charging profiles of lead-acid (flooded, gel, AGM, EFB, traction, stationary), lithium and special industrial batteries to be applied with millisecond precision.
Our systems are custom-built from 2 to 24 channels (e.g. 2, 4, 6, 8, 12, 16, 24 independent channels) with unlimited kW/kVA and ampere ratings to suit the capacity and space requirements of customer plants. High-frequency IGBT Switch-Mode (SMPS) or heavy-duty thyristor-controlled (SCR) topologies can be used in the power electronics. Each channel is equipped with its own 100% independent power stage, transformer group, microprocessor control board and ventilation fan, so a fault on one channel never affects the uninterrupted operation of the others.
The Technical Importance of the Formation Process and Its Effect on Battery Quality
Applying the formation charge correctly during battery manufacturing or maintenance is the main factor determining a battery's service life, cranking/discharge capacity and internal resistance:
- Precise Management of the Electrochemical Conversion: A stepped, recipe-based charging program converts the lead sulphate/oxide structure on the positive and negative plates leaving production into PbO2 and spongy Pb. REDARTI's proprietary formation software prevents plate shedding and excessive gassing.
- Multi-Channel Independent Charging Flexibility: Thanks to the independent architecture of 2 to 24 channels, recipes with different voltages (e.g. 12V - 400V DC) and different currents (e.g. 5 A - 300 A DC) can run simultaneously on different channels of the same rectifier.
Key Features and Hardware Architecture
- Unlimited Power from 2 to 24 Channels: Modular cabinet design with 2, 4, 8, 12, 16 or 24 channels tailored to plant production lines; unlimited ampere and voltage capacity.
- Switch-Mode or Thyristor Power Stage: High efficiency (>95%) and compactness with high-frequency IGBT Switch-Mode, or a rugged heavy-duty thyristor design with transformer.
- Advanced HMI and PC Software Integration: All operating pages, current/voltage graphs and database records can be monitored in real time on the cabinet's industrial colour touchscreen (HMI) or via central PC formation software connected over Ethernet/Profinet.
- Modular Isolation and Robust Hardware: Special copper-wound, impregnation-insulated transformers as shown in the photos, independent driver boards, a Siemens PLC platform and separate fuse/breaker protection for each channel.
- Manual or Automated Control: Either manual parameter entry on the cabinet or recipe loading and fully automatic operation via SCADA / MES factory automation systems.
Applications
- Battery Manufacturing Plants and Production Facilities: Series formation lines of automotive, heavy-vehicle, marine and stationary battery factories.
- Battery Renewal, Recycling and Desulfation Facilities: Recovering the capacity of used or deeply discharged flooded/gel batteries with software-controlled formation charging (desulfation).
- Battery Testing, Certification and R&D Laboratories: Plate and battery life/capacity testing by battery manufacturers and independent test laboratories.
- Large Traction / Forklift Fleet and Maintenance Centres: Periodic cell balancing and initial charging of traction battery fleets in logistics warehouses.
- Defence and Aerospace Battery Facilities: Formation of special military vehicle, submarine and aviation batteries with dedicated charging recipes.
