Fuel Cell Frame Assembly with Counterweight Fill
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Solution Overview
Problem
Conventional lead-acid battery packs in lift trucks provide both power and counterweight, making them unstable when replaced with fuel cell power modules that lack the necessary mass for lifting design loads.
Innovation Solution
A frame assembly for fuel cell power modules with internal cavities filled with high-density materials, such as lead, to replicate the mass and balance weight of battery packs, including a configuration to house fuel cell stacks and storage vessels, and balance of plant components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fuel cell power module replaces a lead-acid battery pack, then maintenance costs and complexity are reduced, but the counterweight mass required for lift truck stability is lost
Solution Approach 1:
The patent combines the fuel cell power module with a counterweight structure into a single integrated assembly. The frame housing that contains the fuel cell stack, hydrogen storage tank, and balance of plant components also serves as the counterweight structure, merging two previously separate functions into one unified component.
Solution Approach 2:
The patent explicitly designs the frame housing with counterweight functionality to compensate for the loss of mass when replacing heavy lead-acid battery packs with lighter fuel cell modules. The counterweight mass is strategically positioned to provide the necessary balance for lift truck stability during operation.
2Duration of action of moving object
If a fuel cell power module is used instead of a battery pack, then continuous operation is enabled, but the lift truck becomes unstable due to insufficient mass
Solution Approach 1:
The frame housing integrates multiple functions: structural support for the fuel cell system, counterweight for stability, and mounting structure for components. This merging ensures that the continuous operation capability of the fuel cell is maintained while simultaneously providing the mass needed for lift truck stability.
Solution Approach 2:
The patent modifies the physical parameters of the frame housing, specifically its mass and density distribution, to achieve the required counterweight effect. By adjusting the mass of the frame structure and positioning components strategically, the system maintains both continuous operation and stability.
3Stability of the object's composition
If lead-acid battery packs are used to provide counterweight, then lift truck stability is maintained, but multiple battery packs are required for continuous operation increasing overall cost
Solution Approach 1:
The frame housing performs multiple functions simultaneously: it provides structural support for the fuel cell system, serves as a counterweight for stability, and houses the hydrogen storage tank and balance of plant components. This multi-functionality eliminates the need for separate counterweight structures and multiple battery packs.
Solution Approach 2:
The patent merges the counterweight function with the fuel cell power module housing, creating a single integrated assembly that replaces both the battery pack and separate counterweight structure. This consolidation reduces the total number of components and simplifies the overall system.
Data Source
AI summary
A frame assembly for a fuel cell power module, particularly but not exclusively for use in lift trucks, has at least one frame element. The frame element is provided with an internal cavity that is filled with a fill material to provide a desired mass of the frame assembly. The frame assembly is configured to receive a fuel cell stack and other balance of plant components of a fuel cell power module and may also be configured to receive a fuel storage vessel. The frame assembly can be configured so that it can replace a battery pack of a lift truck and still provide adequate counterweight.