Construction Machine Battery Rack Assembly for Welding Deformation
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Solution Overview
Problem
Construction machines using electric power from batteries face issues with battery assembly planarity due to deformation during welding, leading to high tensile loads and potential damage, and conventional mounting methods limit productivity.
Innovation Solution
A battery assembly design featuring a rack structure with longitudinal frames and side brackets that secure batteries laterally, preventing planarity-related damage and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batteries are fastened to a planar plate during welding, then assembly is simplified, but deformation during welding causes planarity problems and high tensile loads that may damage batteries
Solution Approach 1:
The planar plate structure is segmented into a three-dimensional rack structure composed of multiple longitudinal frames and transverse frames. This segmentation distributes the welding deformation across multiple independent frame elements rather than a single continuous plate, preventing planarity issues and reducing concentrated tensile loads on batteries.
Solution Approach 2:
The fastening approach transitions from a two-dimensional planar plate to a three-dimensional rack structure. By adding vertical and lateral dimensions through multiple frames positioned at different heights and locations, the structure accommodates welding deformation in multiple directions while maintaining proper battery positioning and reducing stress concentration.
2Ease of operation
If batteries are mounted one by one on the frame, then individual positioning is achieved, but productivity deteriorates
Solution Approach 1:
The rack structure is pre-assembled with multiple longitudinal frames and transverse frames positioned and secured before battery installation. This preliminary framing creates ready-made mounting positions with proper spacing and alignment, allowing batteries to be quickly installed into predetermined locations without requiring complex positioning during the assembly process.
Solution Approach 2:
The rack structure serves multiple functions simultaneously: it provides structural support, defines battery mounting positions, offers welding deformation tolerance, and enables efficient assembly. The standardized frame configuration with multiple longitudinal and transverse elements creates a universal mounting system that can accommodate multiple batteries in various configurations.
Data Source
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AI summary
An aspect of the present disclosure provides a battery assembly of a construction machine including a first rack structure including a plurality of first transverse frames which are fixed to a frame of an upper swing structure of the construction machine, and disposed to be spaced apart from each other in a forward/rearward direction of the construction machine, and a plurality of first longitudinal frames which connect the plurality of first transverse frames to each other, and are disposed to be spaced apart from each other in a leftward/rightward direction of the construction machine, and first batteries mounted between sequential pairs of the first longitudinal frames, respectively, wherein opposite sides of the first batteries are fastened to the first longitudinal frames.