Interchangeable Forklift Powertrain Layout for One Chassis
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Solution Overview
Problem
The manufacturing of forklifts is complicated due to the need for separate chassis designs for gas-powered and electric-powered models, leading to increased costs and inefficiencies, as existing technologies do not allow for a single chassis to accommodate both power sources.
Innovation Solution
The development of an interchangeable power system that enables a single forklift chassis to be used for both internal-combustion and battery-powered forklifts, utilizing a lithium-ion battery pack that is lighter and more efficient than traditional lead-acid batteries, and allowing for variable speed motors to optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate chassis designs are used for gas-powered and electric-powered forklifts, then each power source can be optimized for its specific requirements, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies universality by designing a single chassis platform that can accommodate both internal combustion engines and electric powertrains. The chassis includes standardized mounting locations, battery compartments, and structural elements that work with either power source type, allowing manufacturers to produce one base model that can be configured for different power sources rather than maintaining separate chassis designs
Solution Approach 2:
The patent segments the forklift into modular components: a universal chassis platform and interchangeable power system modules. The power system module includes the engine or motor, battery, fuel tank, and associated components as a replaceable unit that can be swapped on the same chassis, simplifying manufacturing and allowing flexible configuration
2Stability of the object's composition
If traditional lead-acid batteries are used in electric forklifts, then the chassis can be designed with adequate counterbalance, but the battery weight exceeds 1000 pounds and reduces lifting capacity
Solution Approach 1:
The patent applies parameter changes by transitioning from lead-acid battery chemistry to lithium-ion battery chemistry. This chemical parameter change results in batteries that are approximately 60-70% lighter while providing the same or greater energy capacity, allowing the forklift to maintain counterbalance with significantly reduced weight and thereby increase lifting capacity
3Weight of moving object
If lighter lithium-ion batteries are used, then lifting capacity increases, but the batteries may not provide sufficient counterbalance for heavy loads
Solution Approach 1:
The patent applies dimensionality change by moving the battery compartment to the rear of the chassis rather than positioning it centrally or in the counterweight area. This spatial repositioning allows the lighter lithium-ion batteries to provide adequate counterbalance through strategic placement that maximizes their lever arm effect, maintaining stability without requiring heavy batteries
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 simplifies the manufacturing process, reduces costs, and provides a forklift with improved performance and battery life, offering 25% less weight than traditional internal-combustion forklifts while maintaining equivalent lifting capacity and counterbalance, with the option to switch between power sources based on user needs.
Implementation Method 1
utilizing a lithium-ion battery pack that is lighter and more efficient than traditional lead-acid batteries
Data Source
AI summary
A kit for assembling a forklift capable of being either electrically-powered or powered by an internal-combustion source. The kit includes a forklift shell including a chassis and a hydraulic system. The kit further includes an internal-combustion (IC) powertrain including an IC engine, a transmission coupled to the IC engine, a drivetrain coupled with the transmission, and an IC hydraulics pump powered by the IC engine and configured to be coupled with the hydraulic system. The kit further includes an electric powertrain including a battery assembly, an electric motor powered by the battery assembly, a drivetrain coupled with the electric motor, and an electric hydraulics pump powered by the battery assembly and configured to be coupled with the hydraulics system. Where one of the IC powertrain and the electric powertrain is configured to be coupled with the chassis and the hydraulics system for powering operation of the forklift.