Battery Retention Blocks With Auto-Locking Pins for Fast Exchange
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Solution Overview
Problem
Existing materials handling vehicles face challenges in efficiently and securely integrating and removing battery assemblies, particularly in warehouse environments where quick and reliable power is needed for goods movement.
Innovation Solution
A removable battery assembly with a spring-loaded battery handle and locking pin mechanism that allows for easy insertion and removal along a defined axis, combined with a battery receiving space featuring complementary guide pins and electrical connectors for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a removable battery assembly is used in materials handling vehicles, then battery exchange speed and operational efficiency are improved, but secure retention and prevention of accidental disengagement during operation become more difficult
Solution Approach 1:
The battery assembly includes spring-loaded locking pins that are pre-positioned and automatically engage with retaining slots on the vehicle frame when the battery is inserted. This preliminary positioning and automatic locking action ensures secure retention without requiring additional manual steps, thus maintaining high exchange speed while improving retention security.
Solution Approach 2:
The retention system is designed to be self-actuating through spring-loaded locking pins that automatically engage and disengage based on the battery insertion and removal actions. The springs provide automatic resetting of the locking mechanism, eliminating the need for separate locking or unlocking operations and maintaining fast battery exchange while ensuring secure retention during operation.
2Reliability
If a complex locking mechanism is added to secure the battery, then battery retention security is improved, but the device complexity and difficulty of operation increase
Solution Approach 1:
The locking mechanism is merged with the battery assembly structure itself, where the locking pins are integrated into the battery housing rather than being separate components. This integration reduces the number of discrete parts and simplifies the overall system while maintaining secure retention through the spring-loaded engagement with vehicle frame slots.
Solution Approach 2:
The spring-loaded locking pins provide self-actuating engagement and disengagement based on the natural insertion and removal motions of the battery. The springs automatically reset the pins to their engagement position, eliminating the need for complex control systems, multiple actuators, or manual locking operations, thus reducing device complexity while maintaining retention security.
3Ease of operation
If spring-loaded locking pins are used for automatic engagement, then ease of operation is improved, but the force required for insertion and potential for accidental disengagement increase
Solution Approach 1:
The spring-loaded locking pins are positioned at specific locations on the battery assembly where they engage with corresponding slots on the vehicle frame. The springs are pre-loaded to provide sufficient engagement force for secure retention but are designed with controlled stiffness to allow easy insertion when proper force is applied along the insertion axis. This localized optimization of spring properties at specific engagement points balances ease of operation with secure retention.
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
Facilitates quick and secure battery exchange, ensuring uninterrupted power supply in warehouse environments by simplifying the process of battery installation and removal, enhancing operational efficiency.
Implementation Method 1
The spring-loaded locking pin may be spring-biased in an extended position and may be movable relative to the battery body from the extended position to a retracted position along the latch engagement and disengagement axis
Implementation Method 2
The spring-loaded battery handle may comprise a planar handle cam surface and the spring-loaded locking pin may comprise a planar pin cam surface that may be parallel to the handle cam surface. The spring-loaded battery handle and the spring-loaded locking pin may be configured such that the handle cam surface engages the pin cam surface with movement of the battery handle
Data Source
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AI summary
A removable battery assembly (200) comprising a battery body (210), wherein: the battery body (210) defines a longitudinal battery insertion and removal axis along which the battery assembly (200) can be inserted into and removed from a battery receiving space of a materials handling vehicle; the removable battery assembly (200) comprises lateral battery faces (202A), each comprising a longitudinal guide structure (204A) that is oriented along the battery insertion and removal axis (140); the longitudinal guide structure (204A) of each lateral battery face (202A) comprises a one-sided channel portion that terminates in a channel shoulder (2043A) of the longitudinal guide structure (204A); and the one-sided channel portion of the longitudinal guide structure (204A) comprises a lever-receiving detent that is configured to receive a distal end of a retention lever, with the removable battery assembly (200) seated in the battery receiving space.