Multi-scene forklift battery replacement mechanism
By designing a multi-scenario forklift battery replacement mechanism, the system utilizes a bracket body, roller assembly, and electric control to achieve automated adaptation and fixation of batteries of different sizes, solving the problem of poor adaptability of existing devices and improving the efficiency and safety of battery replacement.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ANHUI HELI CO LTD
- Filing Date
- 2026-04-30
- Publication Date
- 2026-06-09
Smart Images

Figure CN122165934A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of forklift technology, and more specifically, to a multi-scenario forklift battery replacement mechanism. Background Technology
[0002] Battery-powered forklifts, as environmentally friendly vehicles, have been applied in various industries and are showing a strong trend of replacing internal combustion engines. However, the power source of electric vehicles has a shorter range compared to internal combustion engines, and the long charging time after parking affects work efficiency. To enable electric vehicles to operate continuously, the most common solution currently is to replace the battery to reduce vehicle downtime.
[0003] However, current battery replacement devices have significant limitations. They require a dedicated battery box for pairing, are incompatible with batteries of different sizes, and cannot be secured after removal, making them prone to damage during movement. Furthermore, these devices cannot be applied to various scenarios, thus limiting their use. Summary of the Invention
[0004] The purpose of this invention is to overcome the problems of poor adaptability, poor fixation stability, and inconvenience of use in the existing technology, and to provide a multi-scenario forklift battery replacement mechanism. This multi-scenario forklift battery replacement mechanism has strong compatibility, reliable fixation, wide applicability, and is easy to use.
[0005] To achieve the above objectives, the present invention provides a multi-scenario forklift battery replacement mechanism, the mechanism comprising: The bracket body has an opening at one end and a guide mechanism is provided at the opening. Multiple sets of roller assemblies are installed at equal intervals along the length of the bracket body inside the bracket body; The fixing mechanism is located in the middle of the interior of the bracket body; The casters are located at the bottom of the bracket body. The upright is located on the side of the bracket body away from the opening. The upright is equipped with an electric drum, which is electrically connected to a controller located on the upright. The pull rope has one end wound around the electric drum and the other end extending through the upright into the bracket body and connected to a hook for pulling the battery to be replaced. The fixing mechanism includes a lifting mechanism, with a fixed seat at the top of the lifting mechanism and movable components around the sides of the fixed seat. A clamping mechanism for holding the battery to be replaced is installed on the movable components.
[0006] Preferably, the movable component has two lengths according to the clamping requirements, which correspond to the length and width of the bracket body respectively.
[0007] Preferably, the lifting mechanism includes a mounting base, which is fixedly connected to the bottom center of the bracket body. An electric lifting rod is mounted on the mounting base, and the piston rod of the electric lifting rod is fixedly connected to the fixed seat.
[0008] Preferably, the movable component includes a slide rail, one end of which is connected to a fixed base, and the other end is equipped with a drive motor. The slide rail is provided with a lead screw, which is connected to the shaft of the drive motor. A movable seat is sleeved on the lead screw. The drive motor drives the lead screw to rotate, which can move the clamping mechanism closer to or away from the fixed base.
[0009] Preferably, the clamping mechanism includes a vertical plate, on which a limiting slide rod is movably connected. A limiting block is provided at one end of the limiting slide rod near the inner wall of the bracket body, and a clamping plate is connected to the other end of the limiting slide rod. Furthermore, a buffer spring is nested on the surface of the limiting slide rod located between the clamping plate and the vertical plate, and the two ends of the buffer spring are fixedly connected to the clamping plate and the vertical plate, respectively.
[0010] Preferably, a pressure sensor is installed in the middle of the side of the upright plate, and the pressure sensor, electric lifting rod and drive motor are all electrically connected to the controller.
[0011] Preferably, rubber pads are installed on the side surfaces of the clamping plate.
[0012] Preferably, the guiding mechanism includes a storage groove on the side of the opening of the bracket body, a guide plate is rotatably connected to the middle of the storage groove, a servo motor is installed on the upper side of the bracket body, the shaft of the servo motor is connected to the shaft of the guide plate, and the servo motor is electrically connected to the controller.
[0013] Preferably, the end of the guide plate away from the servo motor has an arc-shaped structure.
[0014] Preferably, the bottom of the guide plate does not contact the rolling surface of the roller assembly.
[0015] According to the above technical solution, several roller assemblies are installed at equal intervals inside the main body of the bracket. A fixing mechanism is installed in the middle of the main body, and a guiding mechanism is set at the opening of the main body. Through the lateral adjustment function of the moving components and the elastic clamping design of the clamping mechanism, no special battery box is required for pairing. It can adapt to forklift batteries of different lengths, widths, and thicknesses, solving the limitation of traditional replacement devices that can only match batteries of specific sizes, reducing equipment adaptation costs, and providing strong compatibility with batteries of multiple sizes. At the same time, the elastic clamping structure combined with real-time monitoring by pressure sensors ensures that the battery does not shake or shift during movement, and also avoids damage to the battery casing due to excessive clamping force. Furthermore, the cushioning protection of buffer springs and rubber pads further improves the stability and safety of the fixation. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the overall structure of the forklift battery replacement mechanism for multiple scenarios provided by the present invention. Figure 2 This is a schematic diagram of the fixing mechanism in the multi-scenario forklift battery replacement mechanism provided by the present invention; Figure 3 This is a structural schematic diagram of the lifting mechanism in the multi-scenario forklift battery replacement mechanism provided by the present invention; Figure 4 This is a schematic diagram of the structure of the moving component in the multi-scenario forklift battery replacement mechanism provided by the present invention; Figure 5 This is a schematic diagram of the clamping mechanism in the multi-scenario forklift battery replacement mechanism provided by the present invention; Figure 6 This is a schematic diagram of the guide mechanism in the multi-scenario forklift battery replacement mechanism provided by the present invention.
[0017] Explanation of reference numerals in the attached figures 1-Roller assembly, 2-Guide mechanism, 21-Servo motor, 22-Guide plate, 23-Storage slot, 3-Bracket body, 4-Fixing mechanism, 41-Lifting mechanism, 411-Electric lifting rod, 412-Mounting base, 42-Fixing seat, 43-Moving component, 431-Slide rail, 432-Screw rod, 433-Moving seat, 434-Drive motor, 44-Clamping mechanism, 441-Clamping plate, 442-Upright plate, 443-Limit block, 444-Pressure sensor, 445-Buffer spring, 446-Limit slide rod, 447-Rubber pad, 5-Moving wheel, 6-Upright frame, 7-Electric drum, 8-Controller, 9-Pull rope, 10-Hook. Detailed Implementation
[0018] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.
[0019] In this invention, unless otherwise stated, directional terms such as "top," "bottom," "far," "near," and "middle" contained in the terminology represent only the orientation of the term in its conventional use or are common terms understood by those skilled in the art, and should not be regarded as limitations on the terminology.
[0020] See Figures 1 to 6 This invention provides a multi-scenario forklift battery replacement mechanism, which includes: The bracket body 3 has an opening at one end and a guide mechanism 2 is provided at the opening. Multiple sets of roller assemblies 1 are installed at equal intervals along the length direction inside the bracket body 3; Fixing mechanism 4 is located in the middle of the interior of bracket body 3; The movable wheel 5 is located at the bottom of the bracket body 3; The support frame 6 is located on the side of the bracket body 3 away from the opening. The support frame 6 is equipped with an electric drum 7, which is electrically connected to a controller 8 located on the support frame 6. Pull rope 9, one end of which is wound around electric drum 7, and the other end extends through the upright 6 into the bracket body 3 and is connected to a hook 10 for pulling the battery to be replaced. The fixing mechanism 4 includes a lifting mechanism 41, a fixing seat 42 at the top of the lifting mechanism 41, and a moving component 43 around the sides of the fixing seat 42. A clamping mechanism 44 for clamping the battery to be replaced is installed on the moving component 43.
[0021] Through the above technical solution, the moving component 43 in the fixing mechanism 4 can be adjusted laterally. Combined with the clamping mechanism 44, it can accommodate forklift batteries of different lengths, widths, and thicknesses without the need for a dedicated battery box, overcoming the limitation of traditional devices that can only be paired with batteries of specific sizes, and is compatible with batteries of multiple sizes. Furthermore, the guide mechanism 2 at the opening can be unfolded to provide precise guidance for the battery to enter the main body of the bracket, preventing deviation. The roller assembly 1 inside the main body of the bracket 3 reduces friction and assists in the smooth sliding of the battery. The bottom moving wheels 5 allow the mechanism to be flexibly moved to different working positions according to usage needs. The electric drum 7, pull rope 9, and hook 10 achieve automatic pulling and lifting, eliminating the need for manual high-intensity handling or precise alignment, reducing labor costs and operational difficulty, and adapting to various replacement scenarios. Simultaneously, the controller 8 centrally controls the electric drum 7, lifting mechanism 41, moving component 43, and guide mechanism 2, realizing automated processes such as guiding, clamping, lifting, and handling, shortening battery replacement time, ensuring continuous forklift operation, and improving overall efficiency.
[0022] In this embodiment, the movable component 43 preferably has two lengths, corresponding to the length and width of the bracket body 3 respectively, according to the clamping requirements. By providing movable components 43 of corresponding lengths along the length and width directions of the bracket body 3, the clamping mechanism 44 can simultaneously approach and clamp the battery from all four sides, avoiding battery shifting or shaking caused by clamping from only two opposing directions, thus improving the stability of the fixation. Simultaneously, the two lengths of movable components 43 can be adjusted independently to adapt to changes in the battery's length and width. When the battery size changes, the movable component in the length direction adjusts its longitudinal clamping position, and the movable component in the width direction adjusts its lateral clamping position. This allows for matching forklift batteries with different length-to-width ratios without replacing any parts, enhancing the versatility and compatibility of the device. Furthermore, the movable components 43 distributed around the perimeter, in conjunction with the elastic clamping mechanism 44, ensure that pressure is evenly applied to all sides of the battery, preventing localized stress concentration from damaging the battery casing and ensuring that the battery does not shift or shake during movement.
[0023] In this embodiment, preferably, the lifting mechanism 41 includes a mounting base 412, which is fixedly connected to the bottom center of the bracket body 3. An electric lifting rod 411 is mounted on the mounting base 412, and the piston rod of the electric lifting rod 411 is fixedly connected to the fixed seat 42. Thus, the electric lifting rod 411 can push the fixed seat 42 up and down, thereby moving the clamping mechanism 44 to a height corresponding to the middle of the battery side. Regardless of changes in battery thickness, the clamping mechanism can always clamp the battery at the appropriate position on the side, avoiding clamping failure due to excessively thick or thin batteries, and improving compatibility with batteries of different specifications. The mounting base 412 is fixedly connected to the bottom center of the bracket body 3, ensuring that the thrust center of the electric lifting rod 411 is located in the center of the fixed seat 42, resulting in uniform force distribution. During lifting, the fixed seat 42 moves smoothly and vertically, avoiding tilting, ensuring that the clamping mechanisms 44 on both sides approach the battery synchronously on the same horizontal plane, preventing the battery from tilting or shaking during clamping. At the same time, the lifting action works in coordination with the lateral adjustment of the moving component 43 and the elastic clamping of the clamping mechanism 44.
[0024] In this embodiment, preferably, the moving component 43 includes a slide rail 431, one end of which is connected to the fixed base 42, and the other end is equipped with a drive motor 434. A lead screw 432 is provided inside the slide rail 431, and the lead screw 432 is connected to the shaft of the drive motor 434. A movable seat 433 is fitted onto the lead screw 432. The drive motor 434 drives the lead screw 432 to rotate, which in turn moves the clamping mechanism 44 closer to or further away from the fixed base 42. Thus, the drive motor 434 drives the lead screw 432 to rotate, causing the movable seat 433 to move linearly along the slide rail 431, thereby moving the clamping mechanism 44 closer to or further away from the fixed base 42. By controlling the amount of motor rotation, the position of the clamping mechanism can be precisely adjusted to accommodate forklift batteries of different lengths and widths, eliminating the need for manual adjustment. The side of the movable seat 433 is in close contact with the inner wall of the slide rail 431. Combined with the helical drive of the lead screw 432, the movement is smooth and vibration-free, ensuring that the clamping mechanism 44 can be vertically aligned with the side of the battery, preventing unstable clamping or battery damage due to misalignment. Furthermore, a pressure sensor 444 is preferably installed in the middle of the side of the upright plate 442. The pressure sensor 444, the electric lifting rod 411, and the drive motor 434 are all electrically connected to the controller 8. The drive motor 434, electrically connected to the controller 8, works in conjunction with the pressure sensor 444 on the clamping mechanism. When the clamping plate contacts the battery and the pressure reaches a preset value, the controller automatically stops the motor, achieving adaptive fixation. This ensures a secure clamp without wobbling while preventing over-clamping and damage to the battery casing. With this design, the movable component 43 is responsible for lateral (length and width) adjustment, and the lifting mechanism 41 is responsible for vertical (thickness) adjustment. Together, they allow the clamping mechanism to adapt to three different battery sizes, comprehensively solving the limitation of traditional devices that can only accommodate batteries of a single size.
[0025] In this embodiment, preferably, the clamping mechanism 44 includes a vertical plate 442, on which a limiting slide rod 446 is movably connected. A limiting block 443 is provided at one end of the limiting slide rod 446 near the inner wall of the bracket body 3, and a clamping plate 441 is connected to the other end of the limiting slide rod 446. A buffer spring 445 is nested on the surface of the limiting slide rod 446 between the clamping plate 441 and the vertical plate 442, with both ends of the buffer spring 445 fixedly connected to the clamping plate 441 and the vertical plate 442, respectively. When the moving component 43 drives the clamping plate 441 closer to the battery, the buffer spring 445 is compressed, resulting in elastic contact between the clamping plate 441 and the side of the battery. Compared to rigid clamping, this design can absorb impact forces and prevent damage to the battery casing due to sudden changes in clamping force or control errors. Meanwhile, the buffer spring 445 allows the clamping plate 441 to automatically adjust its position within a certain range according to the actual size of the battery. Even if there are slight tolerances in the length and width of the battery, the spring can provide continuous preload to ensure that the battery does not shake or shift during movement. A pressure sensor 444 is installed on the side of the upright plate 442. When the clamping plate 441 is pushed and compressed by the spring, the spring force reacts to the sensor on the upright plate 442 to detect the clamping force in real time. The controller 8 controls the start and stop of the drive motor 434 according to the pressure value. When the preset clamping force is reached, the feed stops to avoid excessive clamping force caused by over-compression of the spring. In addition, one end of the limiting slide rod 446 is limited by the limiting block 443 to limit the maximum extension, and the other end is connected to the clamping plate 441. This ensures that the clamping plate can slide in a straight line and prevents the spring from popping the clamping plate out or the slide rod from disengaging from the upright plate, ensuring reliable operation of the mechanism.
[0026] In this embodiment, a rubber pad 447 is preferably installed on the side surface of the clamping plate 441. Because the rubber pad 447 is flexible and elastic, when the clamping plate 441 contacts the battery, the rubber pad contacts the battery surface first, further absorbing the clamping impact force and preventing the hard clamping plate from directly crushing or scratching the battery casing, forming a double elastic protection with the buffer spring 445. Simultaneously, the rubber material has a high surface friction coefficient, effectively increasing the friction with the battery side after clamping, preventing longitudinal or lateral slippage of the battery due to vibration during transportation or movement, and improving the reliability of the fixation. Furthermore, the rubber pad 447 can deform slightly, adapting to minor bumps or unevenness on the battery casing surface, resulting in a more even distribution of clamping force, avoiding localized stress concentration, and further improving compatibility and fixation stability for batteries in different states.
[0027] In this embodiment, preferably, the guiding mechanism 2 includes a storage groove 23 opened on the side of the opening of the bracket body 3. A guide plate 22 is rotatably connected to the middle of the storage groove 23. A servo motor 21 is installed on the upper side of the bracket body 3. The rotating shaft of the servo motor 21 is connected to the rotating shaft of the guide plate 22, and the servo motor 21 is electrically connected to the controller 8. Thus, after receiving a command from the controller 8, the servo motor 21 drives the guide plate 22 to rotate out or retract from the storage groove 23. When in use, it unfolds to form a guide ramp; when not in use, it retracts into the storage groove, without occupying the internal space of the bracket body, facilitating the movement and storage of the mechanism. When the battery is pulled into the bracket body by the hook 10, the unfolded guide plate 22 forms a guiding slope at the opening, causing the battery to automatically align with the entrance direction of the roller assembly 1, avoiding battery jamming or collision with the bracket edge due to misalignment, and reducing the risk of damage to the battery and equipment. More preferably, the end of the guide plate 22 away from the servo motor 21 has an arc-shaped structure. Meanwhile, the bottom of the guide plate 22 does not contact the rolling surface of the roller assembly 1, thus ensuring that the battery casing will not be scratched or worn during the guiding process. In addition, the unfolding / retraction of the guide plate 22, the movement of the electric drum 7, the lifting mechanism 41, and the moving assembly 43 are all coordinated by the controller, realizing the automation of the entire battery replacement process, shortening auxiliary time, and improving work efficiency.
[0028] The multi-scenario forklift battery replacement mechanism provided by this invention allows the moving wheels 5 at the bottom of the bracket body 3 to flexibly move the entire mechanism to the forklift battery installation position, adapting to the position requirements of different operating scenarios. The servo motor 21 in the guiding mechanism 2 receives instructions from the controller 8 and drives the guide plate 22 to rotate, unfolding from the storage slot 23 to provide precise guidance for the battery to enter the bracket body 3, preventing deviation. When the forklift battery needs to be removed, the controller 8 activates the electric drum 7 on the upright 6, releases the pull rope 9, and manually hooks the battery using the hook 10. The electric drum 7 then retracts the pull rope 9, moving the battery above the bracket body 3. The roller assembly 1 inside the bracket body 3 reduces friction during battery placement, assisting the battery to smoothly slide to the designated position. After the battery is in place, the fixing mechanism 4 begins operation. The electric lifting rod 411 of the lifting mechanism 41 pushes the fixing seat 42 up and down, causing the clamping mechanism 44 to move upward. The drive motor 434 of the moving component 43 drives the lead screw 432 to rotate, causing the moving seat 433 in the slide rail 431 to move laterally. The mechanism moves, causing the upper clamping mechanism 44 to move closer to the side of the battery. The limiting slide bar 446, in conjunction with the buffer spring 445, allows the clamping plate 441 to form an elastic clamp when it contacts the battery, avoiding damage to the battery from hard contact. The pressure sensor 444 detects the clamping force in real time and feeds it back to the controller 8. When the force reaches the preset value, the drive motor 434 stops running, achieving adaptive fixing of batteries of different sizes. After fixing, the mechanism is moved to the target position by the moving wheel 5. The above process is reversed to release the clamping mechanism 44. The electric drum 7 and the hook 10, in conjunction with the guide mechanism 2, accurately install the battery into the designated position, completing the replacement.
[0029] In summary, this invention, on the one hand, utilizes the lateral adjustment function of the moving component and the elastic clamping design of the clamping mechanism to eliminate the need for a dedicated battery box, adapting to forklift batteries of different lengths, widths, and thicknesses. This overcomes the limitations of traditional replacement devices that can only match batteries of specific sizes, reducing equipment adaptation costs and offering strong compatibility with batteries of multiple sizes. On the other hand, the elastic clamping structure, combined with real-time monitoring by pressure sensors, ensures that the battery does not shake or shift during movement, while also preventing damage to the battery casing due to excessive clamping force. The buffer springs and rubber pads further enhance the stability and safety of the fixation. Simultaneously, the servo motor in the guiding mechanism receives commands from the controller and drives the guide plate to rotate, unfolding from the storage slot to provide precise guidance for the battery to enter the main body of the bracket, preventing deviation. Furthermore, the controller enables electric control, eliminating the need for manual high-intensity handling or precise alignment, reducing labor costs and operational difficulty during battery replacement. The automated coordination of guiding, clamping, and lifting functions shortens the replacement time for a single battery, ensuring continuous forklift operation and indirectly improving overall production efficiency.
[0030] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings; however, the present invention is not limited thereto. Within the scope of the inventive concept, various simple modifications can be made to the technical solutions of the present invention, including combinations of various specific technical features in any suitable manner. To avoid unnecessary repetition, the present invention will not describe the various possible combinations separately. However, these simple modifications and combinations should also be considered as the content disclosed in the present invention and are all within the protection scope of the present invention.
Claims
1. A multi-scenario forklift battery replacement mechanism, characterized in that, The institutions include: The bracket body (3) has an opening at one end and a guide mechanism (2) 2 is provided at the opening; Multiple sets of roller assemblies (1) are installed at equal intervals along the length direction inside the bracket body (3); Fixing mechanism (4), the fixing mechanism (4) is disposed in the middle of the interior of the bracket body (3); The movable wheel (5) is located at the bottom of the bracket body (3); A support frame (6) is provided on the side of the bracket body (3) away from the opening. An electric drum (7) is provided on the support frame (6). The electric drum (7) is electrically connected to a controller (8) provided on the support frame (6). Pull rope (9), one end of which is wound around the electric drum (7), and the other end extends through the stand (6) into the bracket body (3) and is connected to a hook (10) for pulling the battery to be replaced. The fixing mechanism (4) includes a lifting mechanism (41), the top of the lifting mechanism (41) is provided with a fixed seat (42), the fixed seat (42) is provided with a moving component (43) around its sides, and the moving component (43) is equipped with a clamping mechanism (44) for clamping the battery to be replaced.
2. The multi-scenario forklift battery replacement mechanism according to claim 1, characterized in that, The moving component (43) has two lengths according to the clamping requirements, which correspond to the length and width of the bracket body (3) respectively.
3. The multi-scenario forklift battery replacement mechanism according to claim 1, characterized in that, The lifting mechanism (41) includes a mounting base (412), which is fixedly connected to the bottom middle of the bracket body (3). An electric lifting rod (411) is mounted on the mounting base (412), and the piston rod of the electric lifting rod (411) is fixedly connected to the fixed seat (42).
4. The multi-scenario forklift battery replacement mechanism according to claim 3, characterized in that, The moving component (43) includes a slide rail (431), one end of which is connected to the fixed base (42), and the other end is equipped with a drive motor (434). The slide rail (431) is provided with a lead screw (432), which is connected to the shaft of the drive motor (434). A moving base (433) is sleeved on the lead screw (432). The drive motor (434) drives the lead screw (432) to rotate, which can drive the clamping mechanism (44) to move closer to or away from the fixed base (42).
5. The multi-scenario forklift battery replacement mechanism according to claim 4, characterized in that, The clamping mechanism (44) includes a vertical plate (442), on which a limiting slide rod (446) is movably connected. A limiting block (443) is provided at one end of the limiting slide rod (446) near the inner wall of the bracket body (3). A clamping plate (441) is connected to the other end of the limiting slide rod (446). A buffer spring (445) is nested on the surface of the limiting slide rod (446) between the clamping plate (441) and the vertical plate (442). The two ends of the buffer spring (445) are fixedly connected to the clamping plate (441) and the vertical plate (442) respectively.
6. The multi-scenario forklift battery replacement mechanism according to claim 5, characterized in that, A pressure sensor (444) is installed in the middle of the side of the upright plate (442). The pressure sensor (444), the electric lifting rod (411), and the drive motor (434) are all electrically connected to the controller (8).
7. The multi-scenario forklift battery replacement mechanism according to claim 5, characterized in that, The side surface of the clamp (441) is fitted with a rubber pad (447).
8. The multi-scenario forklift battery replacement mechanism according to claim 1, characterized in that, The guiding mechanism (2) 2 includes a storage groove (23) opened on the side of the opening of the bracket body (3). A guide plate (22) is rotatably connected to the middle of the storage groove (23). A servo motor (21) is installed on the upper side of the bracket body (3). The rotating shaft of the servo motor (21) is connected to the rotating shaft of the guide plate (22). The servo motor (21) is electrically connected to the controller (8).
9. The multi-scenario forklift battery replacement mechanism according to claim 8, characterized in that, The guide plate (22) has an arc-shaped structure at one end away from the servo motor (21).
10. The multi-scenario forklift battery replacement mechanism according to claim 8, characterized in that, The bottom of the guide plate (22) does not contact the rolling surface of the roller assembly (1).