Battery Pack Rotation and Transfer for Heavy Rack Loading
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Solution Overview
Problem
Existing battery pack loading systems face challenges in safely and efficiently loading heavy battery packs, which can lead to accidents and decreased workability due to the weight and size of the packs.
Innovation Solution
A battery pack loading apparatus featuring a seating unit with a moving die and adjustable connection shaft, a rotation unit with 360-degree rotary plates and grip portions, and transfer units with hooks and rotary rollers, allowing for safe rotation and positioning of battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional rotation apparatus is used to rotate a heavy battery pack, then the battery pack can be rotated by 90 degrees, but it is difficult to use when the battery module is heavy and the rotatable angle is limited
Solution Approach 1:
The patent employs a movable die that can be positioned at different locations along the longitudinal direction of the battery pack, allowing the rotation apparatus to adapt to different battery pack weights and sizes. The movable die moves together with the battery pack during rotation, providing dynamic adjustment capability that enables rotation of heavy battery packs beyond the conventional 90-degree limit.
Solution Approach 2:
The movable die serves as an intermediary between the rotation apparatus and the battery pack. It facilitates the transfer of rotational force while supporting the battery pack's weight, enabling safe and efficient rotation of heavy packs. The die's ability to move along with the battery pack makes it an effective mediator that resolves the contradiction between operational ease and adaptability to heavy loads.
2Ease of operation
If a worker manually turns a heavy battery pack upside down, then the battery pack can be repositioned, but safety and workability deteriorate due to the weight of approximately 100 kg
Solution Approach 1:
The rotation apparatus performs the repositioning operation autonomously without requiring manual intervention. The movable die automatically moves together with the battery pack during rotation, and the apparatus completes the entire repositioning process independently, eliminating safety risks associated with manual handling of heavy battery packs.
Solution Approach 2:
The patent replaces the manual mechanical system with an automated rotation apparatus. Instead of a worker physically turning the battery pack, the apparatus uses a movable die and rotation mechanism to perform the repositioning, substituting human mechanical effort with a controlled mechanical system that ensures safety and reliability.
3Ease of manufacture
If the movable die is fixed at a specific position, then the structure is simple, but it cannot adapt to battery packs of different sizes and weights
Solution Approach 1:
The movable die is designed to move along the longitudinal direction of the battery pack, providing dynamic adaptability to different pack sizes and weights. This dynamic capability is achieved through a guide groove and guide pin mechanism that allows smooth movement while maintaining structural integrity, thus balancing manufacturing simplicity with operational versatility.
Solution Approach 2:
The rotation apparatus is divided into fixed and movable components. The fixed portion provides structural stability and simplicity, while the movable die provides adaptability. This segmentation allows the system to maintain a simple overall structure while incorporating the necessary flexibility to handle different battery pack configurations.
4Ease of manufacture
If the connection shaft length is fixed, then the manufacturing is simple, but it cannot accommodate different battery pack positions during rotation
Solution Approach 1:
The connection shaft is designed with adjustable length capability, allowing it to adapt to different battery pack positions during rotation. The adjustment mechanism enables the connection shaft to extend or retract as needed, providing versatility while maintaining a relatively simple manufacturing process through standardized components and adjustment mechanisms.
Data Source
Figure 1~2
Figure 3
Figure 4(a)~4(b)
AI summary
The present invention relates to a battery pack loading apparatus and a battery pack loading method using the same, and more particularly to a battery pack loading apparatus including a seating unit (100) configured to allow a battery pack (B) to be seated thereon; a rotation unit (200) configured to rotate the battery pack (B) on the seating unit by a predetermined angle; a first transfer unit (300) configured to move the battery pack (B) rotated by the predetermined angle to a predetermined position; and a second transfer unit (400) configured to transfer the battery pack (B) transferred by the first transfer unit (300) to a battery rack (500) and a battery pack loading method using the same.