Battery Module Transfer Jig With Rollers and Winch for Safe Rack Removal
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Solution Overview
Problem
The existing methods for removing battery modules from racks are unsafe and inefficient, particularly when the modules are heavy, as they require ladders or scaffolds, which can lead to worker safety risks and reduced work efficiency.
Innovation Solution
A battery module transfer jig equipped with a base plate, transfer rollers, a winch, and a mounting unit that allows for safe and efficient transfer of heavy battery modules by coupling the winch to the module and using guide rollers to prevent movement, combined with a manual or electric motorized winch for easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a worker manually handles heavy battery modules using a ladder, then the worker can access high位置的 battery modules, but the worker safety deteriorates due to falling risks and the work environment becomes dangerous
Solution Approach 1:
The patent introduces a transfer jig as an intermediary device between the worker and the battery module. The jig includes a base plate with transfer rollers that contact the battery module, a winch for pulling the module onto the jig, and guide rollers for stable positioning. This intermediary device allows workers to handle heavy modules safely at height without direct manual lifting, resolving the contradiction between accessibility and safety.
2Reliability
If safe scaffolds are installed to replace ladders for battery module replacement, then worker safety improves, but work efficiency deteriorates due to cost and time consumption for installation and movement
Solution Approach 1:
The transfer jig is designed as a universal device that can be used for multiple battery module replacements. The mounting unit can be coupled to various positions, and the jig can transfer modules of different sizes (through adjustment of the winch and guide rollers). This multi-functionality allows a single device to replace multiple scaffold installations, improving efficiency while maintaining safety.
3Reliability
If multiple safe scaffolds are installed or moved to replace several battery modules, then worker safety is maintained, but work efficiency deteriorates significantly due to the time required to move scaffolds
Solution Approach 1:
The patent merges multiple functions into a single transfer jig device. Instead of using separate scaffolds for each module replacement, the jig combines the functions of support, lifting, and transfer in one integrated system. The mounting unit with adjustable coupling portions allows the same device to service multiple module positions, eliminating the need to move scaffolds between locations and significantly reducing time loss.
4Device complexity
If workers manually lift heavy battery modules, then no additional equipment is needed, but the risk of falling and work environment danger increases
Solution Approach 1:
The transfer jig serves as a mechanical intermediary that bears the weight of the battery module during transfer operations. The winch mechanism pulls the module onto the base plate, and the guide rollers ensure stable positioning. This intermediary device eliminates the need for workers to manually lift heavy modules, resolving the contradiction between equipment simplicity and worker safety by introducing a relatively simple mechanical aid.
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
The solution enables safe and efficient transfer of battery modules, reducing the risk of accidents and improving work efficiency by allowing workers to handle heavy modules without the need for ladders or multiple scaffolds, enhancing safety and productivity.
Implementation Method 1
a transfer roller configured to transfer a battery module in a horizontal direction
Implementation Method 2
a plurality of guide rollers disposed at outer peripheries of opposite sides of the base plate
Implementation Method 3
a winch on the base plate and configured to be coupled to the battery module that is loaded in a battery module rack, the winch further being configured to separate the battery module from the battery module rack
Data Source
AI summary
A battery module transfer jig can include a mounting unit extending in a first direction, a base plate supported by the mounting unit and extending in a second direction that intersects the first direction, and a plurality of transfer rollers on the base plate and arranged in a series in the second direction. Each transfer roller can have a rotation axis that extends in the first direction. The battery module transfer jig can further include a winch disposed on the base plate and including a wire configured to be coupled to a battery module loaded in a battery module rack. The winch can separate the battery module from the battery module rack when the winch winds the wire.