Forklift Battery Compartment Frame Stability via Lifting Stop
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Solution Overview
Problem
Industrial trucks with battery compartments require deep cuts for easy battery replacement, which compromises the structural stability of the frame, making it difficult to use standard transport devices like hand pallet trucks or forklifts without significant weakening of the frame.
Innovation Solution
The battery pack is supported by rolling or sliding elements near its first end, with a protruding lifting stop at the second end to facilitate easy removal and insertion using standard transport devices, maintaining frame stability through a smaller cutout in the battery compartment base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a deep cutout is made in the battery compartment floor to enable standard transport devices to access the battery pack, then the battery can be easily replaced with standard equipment, but the frame stability of the industrial truck is significantly weakened
Solution Approach 1:
The battery pack is divided into two functional parts: a first end with rolling elements for stability during transport, and a second end with a lifting stop projection for fork insertion. This segmentation allows different parts of the battery to serve different purposes during the replacement process.
Solution Approach 2:
The lifting stop projection extends downward beyond the battery compartment base in the vertical dimension, creating a new access point for forks from below without requiring horizontal cutouts through the floor. This dimensional change enables standard transport devices to access the battery while preserving floor integrity.
2Ease of operation
If the battery compartment floor is deeply cut out to allow fork insertion, then battery replacement becomes feasible with standard devices, but the structural integrity and strength of the battery compartment frame is compromised
Solution Approach 1:
The lifting stop projection acts as an intermediary element that mediates between the battery pack and the transport device forks. It provides the necessary contact point for fork insertion without requiring direct access to the battery underside through floor cutouts.
Solution Approach 2:
The rolling elements at the first end of the battery pack create a simplified support interface that replicates the function of a complex transport mechanism, enabling standard devices to handle the battery without modifying the battery compartment structure.
3Adaptability or versatility
If a deep incision is made in the battery compartment base to reach the battery with forks, then the battery can be accessed and moved with standard transport aids, but the frame distortion occurs and stability is lost
Solution Approach 1:
The lifting stop projection is pre-positioned on the battery pack before insertion into the compartment. This preliminary configuration ensures that when the battery is placed in the compartment, the projection automatically extends beyond the base to provide fork access, eliminating the need for post-installation structural modifications.
Solution Approach 2:
The battery pack design concentrates the interface features (rolling elements and lifting stop) at specific local positions - the first end and second end respectively. This localized quality allows standard transport devices to interact with the battery without requiring global modifications to the battery compartment structure.
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
Enables easy battery replacement with standard transport devices while maintaining the structural integrity of the battery compartment frame, allowing for efficient and stable battery exchange without complex alignment or significant frame distortion.
Implementation Method 1
the battery block accommodated in the battery compartment can be supported in the vicinity of its first end with at least one rolling body or, if necessary, sliding body on the battery compartment floor in such a way that while maintaining this support when being pulled out of the battery compartment can be displaced in the pull-out direction
Data Source
Figure 1~2
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Figure 5~6
AI summary
The truck has a replaceable battery block (13), and a battery case (3) contained in the battery block. The battery case comprises a side grasp opening (7) for insertion of the battery block. A protrusion (21) stands-out down beyond a lower side of a battery case base (5) and away from a front frame section of the battery case base that lies close to the grasp opening. The protrusion is provided as a lift stop for a battery transport device, in particular forklift device, and for lifting and pulling-out the battery block from the battery case.