Adjustable EV Battery Cart Assembly for Compact Service Handling
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Solution Overview
Problem
The existing methods for transporting and storing electric vehicle (EV) batteries are cumbersome due to their large size and weight, requiring extensive equipment and lack of adjustable solutions to accommodate varying battery dimensions, leading to inefficient use of space and equipment in repair facilities.
Innovation Solution
A battery cart assembly with adjustable and independently movable side assemblies, featuring telescoping support columns and locator pins, allowing for secure transport and storage of EV batteries of different sizes, and facilitating easy access for repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mobile hoist is used to transport EV batteries, then the battery can be moved, but the equipment occupies large space and has large footprint
Solution Approach 1:
The cart assembly is divided into two independently movable side assemblies (first and second side assemblies), each capable of supporting the battery independently. This segmentation allows the system to achieve battery transport capability while using smaller, more compact individual components that occupy less space when not in use.
2Adaptability or versatility
If a fixed configuration cart is used, then the structure is simple, but it cannot accommodate batteries of varying sizes
Solution Approach 1:
The cart assembly incorporates adjustable features including telescoping support columns that can extend or retract, and side assemblies that can be independently positioned. These dynamic elements allow the cart to adapt to different battery dimensions while maintaining a relatively simple base structure that can be easily configured.
Solution Approach 2:
The cart assembly is designed with universal adaptability to accommodate various battery sizes and configurations through its adjustable support system. The same basic cart structure can serve multiple battery types by adjusting the support column lengths and side assembly positions, eliminating the need for multiple specialized carts.
3Reliability
If multiple large equipment pieces are used for battery removal, then the battery can be safely handled, but the process becomes cumbersome and space-consuming
Solution Approach 1:
The cart assembly merges the functions of multiple separate equipment pieces into a single integrated unit. The two side assemblies work together with interconnected support columns to provide stable battery handling, combining the capabilities of what would traditionally require separate lifting and positioning devices into one coordinated system.
4Ease of operation
If a scissor lift is used to lower the battery, then the battery can be positioned, but the scissor lift becomes unavailable for other procedures
Solution Approach 1:
The battery positioning and support function is extracted from the scissor lift and transferred to the independent cart assembly. Once the battery is lowered onto the cart, the scissor lift is freed from its positioning duty and can be immediately reused for other procedures, while the cart independently maintains battery support.
Data Source
AI summary
The present disclosure is directed to battery cart for transporting large and heavy electric car batteries. The cart includes a pair of independently movable and positionable cart half assemblies, with each cart half assembly having a pair of battery supports that are slidably positionable and lockable along a center crossbar. Each support includes height adjustable columns. The cart assemblies therefore, are adjustable to support batteries of varying sizes as well as positioning a supported battery to desired height, facilitating repairs to, and transport of, the electric car battery.