Replaceable Battery Guide Blocks for Secure Forklift Battery Exchange
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Solution Overview
Problem
Current materials handling vehicles lack an efficient and secure mechanism for battery insertion and removal, which can lead to operational inefficiencies and potential damage during handling.
Innovation Solution
A removable battery assembly with a spring-loaded battery handle and locking pin mechanism that securely engages with a battery receiving space, allowing for easy insertion and removal while ensuring electrical connectivity and minimizing wear on components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secure battery locking mechanism is implemented, then battery security and reliability are improved, but device complexity increases
Solution Approach 1:
The locking mechanism is divided into separate functional components: a locking pin for securing the battery, a cam surface for actuation, and a spring for maintaining engagement force. This segmentation allows each component to perform its specific function efficiently while keeping the overall design manageable and reliable.
Solution Approach 2:
The spring-loaded locking pin automatically engages with the battery latch upon battery insertion and maintains continuous engagement pressure without requiring external control systems. The cam surface works with the spring to provide automatic locking and unlocking functionality, reducing the need for complex control mechanisms while ensuring reliable battery security.
2Ease of operation
If a spring-loaded locking pin with cam surface is used, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The cam surface is designed with a curved geometry that converts linear spring force into rotational or lateral motion of the locking pin. This curved surface provides a mechanical advantage that amplifies the spring force, enabling easy battery insertion and removal while the curvature itself must be manufactured with sufficient precision to ensure smooth operation.
Solution Approach 2:
The locking pin is designed to move dynamically between locked and unlocked positions based on battery insertion/removal forces. The spring provides continuous force to maintain engagement, and the cam surface translates this into the appropriate locking motion. This dynamic design improves ease of operation but requires precise manufacturing to ensure reliable transition between states.
3Manufacturing precision
If guide pins are added to the battery receiving space, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Guide pins serve as intermediary elements between the battery body and the battery receiving space. These pins physically guide the battery into correct alignment during insertion, ensuring that the battery engages properly with the locking mechanism and electrical connectors. This intermediary structure improves manufacturing precision by providing mechanical alignment guidance.
Solution Approach 2:
The guide pins are positioned in advance within the battery receiving space to pre-establish the correct alignment path for battery insertion. Before the actual locking engagement occurs, the guide pins ensure the battery is properly positioned, preventing misalignment and ensuring that subsequent locking and electrical connection operations proceed correctly.
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
Enhances operational efficiency by facilitating easy battery exchange and maintaining reliable electrical connections, reducing wear and tear on components, and ensuring secure engagement during use.
Implementation Method 1
The spring-loaded locking pin may be spring-biased in an extended position and may be movable relative to the battery body from the extended position to a retracted position
Implementation Method 2
The spring-loaded battery handle may comprise a planar handle cam surface and the spring-loaded locking pin may comprise a planar pin cam surface that may be parallel to the handle cam surface. The spring-loaded battery handle and the spring-loaded locking pin may be configured such that the handle cam surface engages the pin cam surface with movement of the battery handle
Data Source
AI summary
A materials handling vehicle including a battery receiving space, and a removable battery assembly, wherein: the removable battery assembly includes lateral battery faces, each including a longitudinal guide structure; the battery receiving space includes opposing guide blocks, each arranged on opposite sides of the battery receiving space, and each including a securement portion and a replaceable portion; the replaceable portion of each guide block including a friction-inducing surface and a guiding surface; each friction-inducing surface facing an opposing one of the lateral battery faces; and each guiding surface facing an opposing surface of the longitudinal guide structure, with the removable battery assembly seated in the battery receiving space.