Removable Forklift Battery Coupling With Standoff Connector Gap
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Solution Overview
Problem
Existing materials handling vehicles face challenges in efficiently and securely integrating and removing battery assemblies, particularly in ensuring reliable electrical connections and easy battery access.
Innovation Solution
The design incorporates a removable battery assembly with a spring-loaded battery handle and locking pin mechanism, which cooperates with the battery receiving space to define a clear insertion and removal axis, ensuring secure locking and easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a removable battery assembly is used, then ease of operation is improved, but reliability may worsen due to potential connection issues
Solution Approach 1:
The battery assembly includes pre-configured locking pins and cam surfaces that automatically engage with the vehicle's battery latches during insertion. This preliminary configuration ensures that electrical connections are established before mechanical locking occurs, preventing connection issues during the removable operation cycle.
Solution Approach 2:
The patent introduces electrical connectors as intermediary components between the battery assembly and vehicle electrical system. These connectors include contact elements that maintain electrical continuity throughout the insertion and removal process, mediating between the need for easy battery access and reliable electrical connection.
2Reliability
If a locking mechanism is added to secure the battery, then reliability is improved, but device complexity worsens
Solution Approach 1:
The locking mechanism merges multiple functions into unified components: the locking pins simultaneously provide mechanical retention and electrical connection, while the cam surfaces integrate the locking action with the insertion motion. This merging reduces the number of separate components needed while maintaining reliable battery securing.
Solution Approach 2:
The spring-loaded locking pins automatically engage with the battery latches when the assembly is inserted, and the cam surfaces automatically disengage the locks when the handle is pulled. This self-service mechanism eliminates the need for separate locking or unlocking actions, reducing operational complexity while ensuring reliable securing.
3Ease of operation
If spring-loaded components are used for automatic locking, then ease of operation is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The cam surfaces on the locking pins and corresponding cam surfaces on the battery latches are designed with matched geometries that create equipotential engagement zones. This design ensures that minor variations in manufacturing precision do not prevent proper engagement, as the cam surfaces can accommodate small misalignments while still achieving reliable locking.
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
This solution enhances the efficiency and safety of battery integration and removal, maintaining reliable electrical connections and reducing wear on components, while allowing for easy access and maintenance.
Implementation Method 1
The spring-loaded locking pin may be spring-biased in an extended position and may be movable relative to the battery body from the extended position to a retracted position
Implementation Method 2
The spring-loaded battery handle may be spring-biased in a locked position and may be movable relative to the battery body from the locked position to an unlocked position
Data Source
AI summary
A materials handling vehicle including a battery receiving space, and a removable battery assembly, wherein: the removable battery assembly includes a battery body, a leading face, and an electrical socket on the leading face of the removable battery assembly; the battery receiving space includes an electrical connector; the leading face of the removable battery assembly rests on a bottom surface of the battery receiving space with the electrical socket engaged with the electrical connector; and the electrical socket, the electrical connector, the battery body, and the battery receiving space are configured to define a standoff gap between opposing surfaces of the electrical socket and the electrical connector, with the leading face of the removable battery assembly resting on the bottom surface of the battery receiving space.