Battery Pack Transfer Jig With Guide Rollers for Rack Loading
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Solution Overview
Problem
Conventional methods of loading battery packs into battery racks require significant manual effort and can cause friction, leading to worker fatigue and potential defects due to increased friction, while also increasing product volume and manufacturing costs.
Innovation Solution
A transfer jig with guide rollers is used to minimize friction by allowing easy sliding and mounting of battery packs, featuring first, second, and third guide rollers for stability and safety during loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If rollers are formed in every receiving space of the battery rack to minimize friction, then the battery pack can be loaded without friction, but the volume of the product increases and manufacturing costs increase
Solution Approach 1:
A transfer jig is introduced as an intermediary device between the battery pack and the battery rack. The transfer jig includes rollers that contact the battery pack, allowing it to be moved into the battery rack without direct contact between the battery pack and the rack structure. This mediator approach provides the friction-reducing benefit without requiring rollers to be permanently installed in every receiving space of the battery rack, thus avoiding the volume and cost penalties.
Solution Approach 2:
The transfer jig is designed to be movable and repositionable rather than fixed. It can be moved to different receiving spaces as needed, transforming the static battery rack structure into a dynamic system where the rolling function is provided only when and where required. This dynamic approach eliminates the need for permanent roller installations in all receiving spaces.
2Ease of operation
If rollers are formed in every receiving space of the battery rack, then friction is eliminated during loading, but manufacturing costs increase
Solution Approach 1:
The transfer jig serves as a separate, movable intermediary device that provides the roller function without being permanently integrated into the battery rack structure. This allows the battery rack to be manufactured without expensive roller components in each receiving space, while still achieving friction-free loading through the transfer jig that can be moved to different positions as needed.
Solution Approach 2:
The transfer jig is designed as a relatively simple, movable device that can be manufactured at lower cost compared to integrating rollers into every receiving space of the battery rack. It serves its purpose for each loading operation and can be moved or repositioned, providing an economical solution that avoids the high manufacturing costs of permanently installed rollers in all receiving spaces.
3Productivity
If a worker forcibly pushes the battery pack into the battery rack, then the battery pack can be loaded, but worker fatigue increases and friction may cause defects
Solution Approach 1:
The manual pushing action is replaced by a roller-based mechanical system in the transfer jig. The rollers convert the sliding friction that occurs during forced pushing into rolling friction, which is significantly lower. This mechanical substitution reduces the effort required by the worker while maintaining or improving loading speed, as the rollers facilitate smoother and easier movement of the battery pack into the rack.
Solution Approach 2:
The transfer jig with rollers acts as an intermediary between the worker and the battery pack, reducing the direct mechanical interaction and effort required. Instead of the worker directly pushing the heavy battery pack against friction, the rollers mediate the interaction, reducing the force needed and thereby decreasing worker fatigue while maintaining productivity.
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
Reduces worker fatigue and shortens work time by enabling easy loading of battery packs with minimal force, improving work efficiency and safety.
Implementation Method 1
A transfer jig configured to load a battery pack in a battery rack according to the present invention includes first guide rollers, on which the battery pack is seated, whereby it is possible to move and load the battery pack without a separate transfer device
Data Source
Figure 1
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AI summary
Disclosed are a transfer jig configured to load a battery pack in a battery rack and a battery pack loading method using the same, and more particularly a transfer jig (200) configured to load a plurality of battery packs (300) in a battery rack (100), the battery rack including a plurality of vertical frames (110) spaced apart from each other by a predetermined distance and a plurality of L-shaped horizontal frames (120) located spaced apart from each other by a predetermined distance in a height direction of each of the vertical frames (110) so as to form a receiving space configured to allow each of the battery packs (300) to be received therein, wherein the transfer jig (200) includes a pair of side frames (210) spaced apart from each other by a predetermined distance; a plurality of front frames (220) located perpendicular to the side frames (210); and a plurality of guide rollers (230), and a battery pack loading method using the same.