Battery Module Transfer Jig With Winch and Guide Rollers
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Solution Overview
Problem
Existing methods for separating battery modules from racks are unsafe and inefficient, particularly when dealing with heavy modules, posing a risk to workers and reducing work efficiency.
Innovation Solution
A battery module transfer jig equipped with a base plate, transfer rollers, guide rollers, a winch, and mounting units, allowing safe and efficient transfer of battery modules using a manual winch and adjustable coupling mechanisms to fit various lifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a worker manually separates battery modules from a battery module rack, then the worker can perform maintenance and inspection, but the worker faces high risk of falling and the work environment becomes dangerous due to the heavy weight of battery modules
Solution Approach 1:
The patent introduces a transfer jig as an intermediary device between the worker and the heavy battery module. The transfer jig includes a base plate, transfer rollers, and a winch system that collectively serve as a mechanical mediator to lift and transfer the battery module, eliminating the need for the worker to directly handle the heavy module and thus removing the falling risk.
Solution Approach 2:
The transfer jig enables the battery module to be transferred through self-service mechanisms where the winch system automatically winds the wire to pull the module onto the transfer rollers, and the guide rollers automatically guide the module's movement. This automated self-service process eliminates manual lifting by workers, improving safety.
2Reliability
If a safe scaffold is installed to replace manual handling of battery modules, then worker safety is improved, but work efficiency is reduced due to installation cost and time, and moving the scaffold for multiple modules takes much time
Solution Approach 1:
The transfer jig is designed as a dynamic, movable device that can be easily repositioned along the battery module rack. Unlike a fixed scaffold, the transfer jig can be moved to different locations by simply adjusting its position on the rack, allowing rapid response to multiple maintenance needs without the time-consuming process of installing and moving heavy scaffolds.
Solution Approach 2:
The transfer jig serves multiple functions: it acts as a lifting device, a transfer mechanism, and a positioning system all in one device. The winch system can handle multiple battery modules sequentially, and the guide rollers accommodate different module positions, making the single device universally applicable for various maintenance tasks along the rack.
3Quantity of substance
If battery modules are made larger to increase capacity, then energy storage capability is improved, but the weight increases making manual handling more dangerous
Solution Approach 1:
The transfer jig employs the winch system to provide an upward counteracting force against the gravitational force acting on the heavy battery module. The winch wire winds around the module's lifting groove, creating a counterweight effect that balances the module's weight, allowing safe transfer without direct manual lifting.
Solution Approach 2:
The patent replaces the manual mechanical lifting system (worker's muscles and arms) with a winch-based mechanical system. The winch converts rotational motion into linear pulling force, substituting human mechanical capability with a more powerful and safer mechanical system capable of handling increased module weights from larger capacity batteries.
4Manufacturing precision
If guide rollers are added to prevent battery module movement errors, then transfer precision is improved, but device complexity increases
Solution Approach 1:
The guide rollers are strategically positioned at specific locations where the battery module makes contact during transfer. Rather than providing guidance along the entire path, the guide rollers are placed only at critical points where movement control is needed, such as where the module enters the transfer area and where it is positioned relative to the rack. This localized approach provides necessary precision without adding complexity throughout the entire system.
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 jig enables safe and efficient transfer of heavy battery modules by preventing separation during movement and ensuring alignment with commercial lifts, enhancing worker safety and productivity.
Implementation Method 1
a transfer roller configured to transfer a battery module in a horizontal direction
Implementation Method 2
a winch configured to separate the battery module from the battery module rack, the winch comprising a wire wound around the battery module
Data Source
AI summary
Discussed is a battery module transfer jig including a base plate having mounted thereto a transfer roller configured to transfer a battery module in a horizontal direction, a plurality of guide rollers disposed at outer peripheries of opposite sides of the base plate, 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, and a mounting unit coupled to a lower part of the base plate, wherein the battery module may be easily and safely separated from the battery module rack, whereby it is possible to improve work safety.