Lead-acid batteries remain a critical component in energy storage systems due to their cost-effectiveness, reliability, and ease of manufacturing. Despite the emergence of newer battery technologies, lead-acid batteries are still widely used in applications such as backup power supplies, electric vehicles, industrial machinery, and renewable energy systems. However, one of the major factors influencing their performance and operational lifespan is the design of the positive grid structure. Specifically, the orientation and configuration of horizontal bars within the grid significantly affect current distribution, which in turn influences corrosion patterns and degradation rates.Uneven current flow caused by suboptimal grid design leads to localized corrosion, resulting in decreased battery efficiency and a shortened service life. While previous research has explored the concept of tilting horizontal bars toward the lug to improve performance, these studies often used arbitrary angle values without identifying an optimal design configuration. This study addresses this limitation by conducting a comprehensive computational analysis of horizontal bar angles in lead-acid battery grids. Using finite element modeling techniques, the study evaluates the impact of different tilt angles on current density distribution and identifies configurations that minimize corrosion while enhancing overall battery efficiency.The results reveal that optimizing the bar angle can lead to more uniform current distribution, reducing localized degradation and extending battery life. This research contributes valuable technical insights into grid design, offering practical recommendations for improving the reliability and longevity of lead-acid batteries across diverse operating conditions.
Samir et al. (Wed,) studied this question.