Battery Tray Support Rails for Industrial Truck Exchange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery replacement systems for industrial trucks require changes to the vehicle frame to accommodate different battery removal variants, leading to inefficiencies and increased costs.
Innovation Solution
The system employs separate support strips or U-shaped support rails that surround the battery tray, with downward-pointing contact surfaces and locking mechanisms, allowing for flexible battery handling without altering the vehicle frame, and includes features like telescopic guides and roller conveyors for secure and convenient battery removal and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate support strips or U-shaped support rails are used instead of integrated battery trough supports, then adaptability to different battery removal variants is improved, but device complexity increases
Solution Approach 1:
The support structure is divided into separate, detachable support strips or U-shaped support rails that can be independently attached and removed from the battery trough. These segmented components allow different attachment configurations (e.g., front support, rear support, side supports) to accommodate various battery removal methods without requiring a completely different battery trough design.
Solution Approach 2:
The support strips and U-shaped support rails are designed as universal components that can be attached to different battery trough configurations and work with multiple battery removal variants. The same support rail design can be used across different truck models and battery types, providing multi-functionality and reducing the need for model-specific components.
2Adaptability or versatility
If the vehicle frame is modified to accommodate different battery removal variants, then adaptability is improved, but manufacturing costs and manufacturing complexity increase
Solution Approach 1:
The adaptability features are extracted from the vehicle frame and relocated to detachable support components (support strips and U-shaped support rails). This allows the vehicle frame to remain standardized and simple to manufacture, while the extracted support components provide the necessary variability for different battery removal methods.
Solution Approach 2:
The support structure transitions from a fixed, frame-integrated design to a dynamic, reconfigurable system where support strips and U-shaped rails can be attached and detached as needed. This dynamic configuration allows the same vehicle to adapt to different battery removal variants without permanent modifications to the frame.
3Ease of operation
If support elements protrude above the upper edge of the battery trough, then ease of battery handling is improved, but the overall height of the truck increases
Solution Approach 1:
Instead of providing handling features that protrude vertically above the battery trough, the design uses lateral extensions (downward-pointing contact surfaces on U-shaped support rails) that extend in the horizontal dimension. This dimensional shift allows battery handling features to be accessible without increasing the vertical height of the truck.
Data Source
Figure 1~4
Figure 5~7
Figure 8~9
AI summary
Battery exchange system for a battery-electrically operated industrial truck, in which the frame of the industrial truck has a battery compartment open to the side of the industrial truck for the lateral insertion and removal of a battery tray, wherein at least one laterally projecting support element with a downwardly facing support surface is attached to at least two opposite sides of the battery tray, and the battery compartment has horizontally parallel spaced support surfaces on opposite sides, on which the support elements rest with their bearing surfaces when the battery tray is inserted into the battery compartment.