Configurable Service Cart for Electric Vehicle Battery Handling
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Solution Overview
Problem
The removal and maintenance of electric vehicle batteries are challenging due to their size and weight, requiring specialized and expensive tools that are cumbersome and difficult to store, making servicing inefficient and time-consuming.
Innovation Solution
A service cart with a modular frame, adjustable cross members, and a braking system, designed to support and move electric vehicle batteries safely, featuring a tow hitch for external towing assistance, allowing for compact storage and easy maneuverability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specialized tools are used for battery removal and maintenance, then the reliability of battery servicing is improved, but the device complexity and storage difficulty increase
Solution Approach 1:
The patent combines multiple specialized tools (battery lift, transport cart, positioning mechanisms) into a single integrated service cart platform. The frame structure integrates support surfaces, lifting mechanisms, and transport capabilities, eliminating the need for separate specialized tools while maintaining servicing reliability.
Solution Approach 2:
The service cart is designed as a universal platform that can service different battery types and configurations. The adjustable frame members and configurable support surfaces allow the same device to handle various battery sizes and shapes, replacing multiple specialized tools with one multi-functional unit.
2Ease of operation
If batteries are removed from vehicle chassis for servicing, then the ease of battery maintenance is improved, but the time required and difficulty of removal increase
Solution Approach 1:
The service cart provides a mobile platform that can be positioned directly at the battery location, eliminating the need to move the heavy battery to a fixed workshop. The cart's wheels and braking system enable easy positioning, keeping the battery at its installation location while providing maintenance capabilities.
Solution Approach 2:
The service cart features adjustable and reconfigurable frame members that can be dynamically adjusted to match different battery configurations. The cross members can be repositioned along the brace members to accommodate various battery lengths, and the support surfaces can be adjusted to match battery contours.
3Reliability
If a stable support system is provided for heavy batteries, then the reliability of battery handling is improved, but the weight and complexity of the support structure increase
Solution Approach 1:
The support structure is divided into modular components including separate brace members, cross members, and support surfaces that can be independently adjusted. This segmentation allows the structure to achieve stability through proper geometry and distribution of load rather than through excessive material weight.
Solution Approach 2:
The service cart uses adjustable geometric parameters of the frame structure (cross member positions, support surface angles, brace member spacings) to optimize stability for different battery weights and configurations, rather than designing for maximum weight with fixed heavy structure.
4Ease of operation
If the service cart is designed for compact storage, then the ease of storage is improved, but the accessibility and maneuverability may be reduced
Solution Approach 1:
The frame members are designed to be reconfigurable during both storage and operation. The cross members can be moved along the brace members to collapse the frame into a compact configuration for storage, or expanded to provide adequate support span for different battery sizes during operation.
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
The service cart facilitates efficient and safe handling of electric vehicle batteries by providing a stable support system, easy mobility, and compact storage, reducing the effort required for maintenance and repair operations.
Implementation Method 1
a second number of brake housings having a brake, each of the brake housings operably coupled to one of the first number of wheels and configured to apply a braking force to its respective wheel when its brake is engaged
Data Source
AI summary
A service cart and associated apparatus that is suitable for servicing electric vehicles and vehicle batteries. The service cart may comprise a frame having a number of members that may be arranged in a compact configuration. The service cart may comprise a number of support pads that may be adjustably arranged with respect to the frame. The support pads may comprise an overload protection mechanism having a break pin. The service cart may comprise a detachable handle operable to selectively disengage a number of brakes on the cart. The service cart may comprise a tow hitch suitable for detachably coupling an external tow device.