Battery Exchange Locking Assembly for Rough-Track Load Handlers
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Solution Overview
Problem
Existing load handling devices in storage and retrieval systems face significant downtime due to battery charging, and there is a need for a secure and efficient system to exchange batteries in such devices, especially when operating on rough tracks.
Innovation Solution
A power source exchange system with a compartment and an end effector that allows for automated and secure locking and unlocking of power sources, using a simple rotational movement to engage and disengage the power source, and a locking assembly that moves between locked and unlocked positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rechargeable battery is charged in situ at a charging station, then the battery can be recharged, but the load handling device experiences significant downtime for hours
Solution Approach 1:
The battery is extracted from the load handling device and removed to a separate charging station, allowing the device to operate continuously while the battery is recharged externally. This separation eliminates charging downtime by enabling parallel operation of device and battery charging processes.
Solution Approach 2:
Batteries are pre-charged at the charging station before being installed in the load handling device. This preliminary charging action ensures that a fully charged battery is always available for immediate installation, eliminating waiting time during operation.
2Loss of time
If the battery is made exchangeable to reduce charging downtime, then the exchange time is reduced, but the battery must be securely held during operation on rough tracks
Solution Approach 1:
The locking mechanism is pre-positioned in the locked state before the battery is installed. This preliminary locking action ensures the battery is immediately secured upon installation, preventing any movement or dislodgement during operation on rough tracks while enabling rapid exchange.
Solution Approach 2:
The locking mechanism automatically engages when the battery is inserted into the compartment, without requiring manual intervention. This self-locking feature ensures secure retention during operation while maintaining rapid exchange capability.
3Productivity
If an automated system is implemented for battery exchange, then exchange efficiency is improved, but the system complexity increases
Solution Approach 1:
The end effector automatically performs the complete battery exchange sequence including approach, engagement, locking mechanism actuation, and battery removal without human intervention. This automation increases productivity while the self-service nature of the locking mechanism keeps the system relatively simple.
Solution Approach 2:
The end effector is designed with multi-functionality to both manipulate the battery and actuate the locking mechanism using the same rotational motion. This universal approach consolidates multiple functions into a single component, improving efficiency without proportionally increasing complexity.
4Ease of operation
If the end effector performs only simple rotational movement to unlock and engage the power source, then the operation is simplified, but the mechanism must simultaneously move the locking member
Solution Approach 1:
The locking mechanism is merged with the end effector's rotational motion, so that the same rotation that engages or disengages the battery also actuates the locking member. This combination simplifies operation by using a single motion while the integrated design manages the complexity of coordinating multiple functions.
Solution Approach 2:
The end effector's rotational movement serves multiple functions simultaneously: it engages or disengages the battery from the compartment and actuates the locking mechanism. This multi-functionality simplifies the operational sequence while the integrated mechanism manages the complexity of achieving both functions with one motion.
Data Source
AI summary
The present disclosure relates to a power source exchange system and a method for exchanging a power source. The power source exchange system comprises a compartment configured to removably receive a power source, a rotatable end effector, and a locking assembly. Rotation of the end effector can move the locking member from the locked position to the unlocked position. A load handling device is provided for lifting and moving containers arranged in stacks in a storage structure. The load handling device comprises the compartment, and a power source received into the compartment is configured to deliver electrical power to the load handling device. A storage and retrieval system is provided, comprising the storage structure, load handling device, and power source exchange system. Methods are provided of inserting a power source into the compartment of the power source exchange system, removing a power source, and exchanging a power source.