Battery Transfer Apparatus with Rollers for Forklift Downtime
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Solution Overview
Problem
The process of replacing batteries in materials handling vehicles, such as forklift trucks, is cumbersome due to the large and heavy nature of the batteries, requiring them to be extracted and transported for recharging, which takes time and disrupts vehicle operations.
Innovation Solution
A battery transfer apparatus comprising a mobile unit with rollers for supporting and transporting batteries, and a battery stand for storage, allowing for efficient loading and unloading of batteries from vehicles without the need for on-board recharging, which keeps the vehicle operational.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If batteries are extracted and transported for recharging, then recharging can be performed off-vehicle, but the process becomes time-consuming and disrupts vehicle operations
Solution Approach 1:
The battery stand is positioned in advance near the vehicle, and the transfer apparatus is prepared with rollers and engagement mechanisms ready to immediately receive and transport the battery to the recharging station, eliminating setup time during the actual replacement operation
Solution Approach 2:
A dedicated transfer apparatus with rollers and engagement mechanisms serves as an intermediary system between the vehicle battery compartment and the recharging station, enabling seamless battery transport without manual handling and reducing overall transfer time
2Use of energy by moving object
If large and heavy batteries are extracted from vehicles, then recharging can be performed, but the operation becomes difficult and time-consuming
Solution Approach 1:
The transfer apparatus with rollers and engagement mechanisms serves as an intermediary system between the vehicle battery compartment and the recharging station, enabling seamless battery transport without manual handling and reducing overall transfer time
Solution Approach 2:
The battery stand is positioned at the same vertical level as the vehicle battery compartment, and the transfer apparatus operates on a level surface, eliminating the need to lift or lower heavy batteries vertically and reducing operational difficulty
3Productivity
If on-board recharging is implemented, then vehicle operation continuity is maintained, but the vehicle must be out of service during recharging
Solution Approach 1:
The battery is extracted from the vehicle and placed on a dedicated battery stand positioned near the vehicle, allowing the battery to be recharged externally while the vehicle remains in service or is quickly returned to service, separating the recharging operation from the vehicle's operational cycle
Solution Approach 2:
A charged battery is staged on the battery stand in advance near the vehicle, so that when the current battery needs replacement, the charged battery is already positioned and ready for immediate installation, minimizing vehicle downtime
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 efficient battery replacement and storage, reducing downtime for materials handling vehicles by enabling off-vehicle recharging and maintaining vehicle availability during battery transfer operations.
Implementation Method 1
The load handling structure comprises at least one roller that is used to roll the battery into or out of the materials handling vehicle
Data Source
AI summary
A battery transfer apparatus for loading/unloading batteries from materials handling vehicles includes a mobile unit and a battery stand. The mobile unit is used to transport batteries into/out of materials handling vehicles and includes load handling structure comprising at least one roller, which is used to roll batteries into/out of materials handling vehicles. A top wall of the battery stand includes at least one opening and support structure of the battery stand engages a surface so as to support the battery stand thereon. The battery stand is engaged by the mobile unit during battery transfer operations by inserting the roller(s) up through the opening(s) in the top wall of the battery stand such that the roller(s) can engage the battery through the opening(s). The battery stand is capable of storing the battery while the battery is out of the materials handling vehicle.