Battery Tray Roller-Jig Fitting for Heavy Pack Replacement
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Solution Overview
Problem
As battery packs increase in size and weight, they become difficult to assemble and replace due to limited ease of movement, making existing battery devices inefficient for installation and removal.
Innovation Solution
A battery device with a rack and battery unit system, where the battery tray features a fitting portion for a roller jig, allowing easy sliding and installation, and a jack jig for jacking up the unit, facilitating efficient assembly and replacement by improving the 'case of movement' and alignment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery pack size and weight are increased to improve energy storage capacity, then the energy storage capacity is improved, but the ease of assembling and replacing the battery pack deteriorates
Solution Approach 1:
A roller jig is introduced as an intermediary tool between the battery pack and the rack. The roller jig includes rollers that engage with the battery pack and a handle for manual operation, allowing workers to easily move heavy battery packs into and out of the rack without directly lifting or carrying them.
Solution Approach 2:
The system is segmented into distinct components: the battery pack, the roller jig, and the rack with guide rails. This segmentation allows each component to have a specialized function, with the roller jig serving as a dedicated moving aid that can be attached to and removed from the battery pack as needed.
2Quantity of substance
If the battery pack size and weight are increased to improve energy storage capacity, then the energy storage capacity is improved, but the ease of movement deteriorates
Solution Approach 1:
The roller jig acts as a mediator that transfers the movement function from the battery pack itself to an external tool. The rollers in the jig reduce friction between the battery pack and the rack surface, while the handle provides mechanical advantage for the user.
Solution Approach 2:
The manual lifting and carrying mechanism is replaced with a rolling mechanism. Instead of directly applying force to move the heavy battery pack, the roller jig converts linear motion into rolling motion, significantly reducing the force required and improving ease of movement.
3Ease of operation
If a roller jig is attached to the battery tray to improve ease of movement, then the ease of movement is improved, but the device complexity increases
Solution Approach 1:
The roller jig is designed to be dynamically attachable and detachable rather than permanently fixed. The fitting portion on the battery tray allows the roller jig to be attached when needed for moving battery packs and removed when not needed, maintaining simplicity during normal operation while providing enhanced functionality when required.
Solution Approach 2:
The roller jig serves multiple functions: it provides rolling elements for easy movement, includes a handle for manual operation, and can be attached to different battery packs through the standardized fitting portion. This multi-functionality justifies the added complexity by providing versatile utility.
Data Source
AI summary
A battery device includes a rack including a support member, and a battery unit installed on the support member of the rack. The battery unit includes a battery tray and a battery pack mounted on the battery tray. An outer peripheral portion of the battery tray includes a fitting portion configured to fit with a roller jig configured to slide the battery unit on the support member.