Battery Block Removal Lever for Industrial Trucks
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Solution Overview
Problem
Existing locking devices for battery packs in industrial trucks require high force to remove due to settling of roller contact surfaces during transport and lack sufficient space for easy hand access, making battery changes cumbersome.
Innovation Solution
A locking device with a separate removal lever and a battery lock that allows partial pushing of the battery pack out of the frame, featuring a handle section with holding stops and a curved lever contour for enhanced leverage, enabling easier removal and preventing accidental rolling or pinching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional locking device with toggle lever lock is used, then the battery pack can be securely locked in the frame, but high force is required to remove the battery pack due to settling of roller contact surfaces
Solution Approach 1:
The locking device is segmented into two independent functional components: a battery lock for securing the battery pack and a separate removal lever for facilitating battery pack removal. This segmentation allows each component to be optimized independently - the battery lock provides secure retention while the removal lever with its lever arm provides mechanical advantage for easy removal, resolving the contradiction between secure locking and ease of removal.
Solution Approach 2:
The removal lever acts as an intermediary tool between the operator and the battery pack. It provides a lever arm that amplifies the operator's input force to overcome the breakaway force from settled roller contact surfaces, enabling easy battery pack removal without requiring direct high force application.
2Stability of the object's composition
If the battery pack is locked securely in the frame, then the battery pack remains stable during operation, but there is little or no space for hand access behind the battery for removal
Solution Approach 1:
The removal lever is designed to automatically perform the preliminary action of pushing the battery pack outward from its locked position. When the battery lock is released, the removal lever can be actuated to partially push the battery pack out of the frame, creating the necessary clearance space for hand access behind the battery without requiring manual maneuvering in a confined space.
Solution Approach 2:
The removal lever serves as an intermediary mechanism that creates space for hand access. It pushes the battery pack outward to a predetermined position where sufficient clearance exists for the operator's hand to reach behind the battery, solving the access problem while maintaining secure locking during operation.
3Ease of operation
If the battery pack is allowed to move freely after unlocking, then easy removal is possible, but the battery pack may roll out or be pinched causing injury or damage
Solution Approach 1:
The removal lever is designed with a controlled movement path that performs preliminary action to partially push the battery pack out to a safe intermediate position. This predetermined movement path ensures the battery pack is moved to a position with sufficient clearance for hand access while maintaining control to prevent uncontrolled rolling or pinching hazards.
Solution Approach 2:
The removal lever incorporates a self-limiting mechanism where the battery pack itself, through its interaction with the lever and frame, provides feedback that limits the lever's travel. The battery pack's own geometry and position serve to control the removal process, automatically stopping at a safe position that prevents rolling or pinching while enabling easy removal.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates quick and easy battery changes by reducing the force required for removal and ensuring safe access, even on inclines, while preventing the battery pack from rolling out or being pinched during insertion or removal.
Implementation Method 1
the lever effect can easily be used to break loose
Data Source
Figure 1~2
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Figure 5~6
AI summary
The device has a battery lock (10) detachably locking a battery block in a frame of an industrial truck. A separate removing lever (20) is mounted around an axle (11) and supports removal of the block. The lever includes a gripping section (21) and a lever section (22) formed by respective lever arms. The lever section partially pushes the block out of the frame during removing the block. The lever is connected with the block via the axle. The gripping section includes a holding stop, which limits movability of the block from the frame in an idle position of the lever.