Compact Loader Battery Swap Using Auxiliary-Powered Removal
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Solution Overview
Problem
Existing battery-powered work machines face challenges in efficiently and conveniently exchanging heavy batteries, especially when power levels are low, requiring additional equipment for removal and potentially leaving the machine stranded.
Innovation Solution
A work machine equipped with a battery removal system powered by a secondary battery, allowing for easy disconnection and exchange of primary batteries using mechanisms like cranes or slides, even in low-power modes, with features like cammed levers and subframes for secure attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a heavy battery is used to power the work machine, then the power and duration of action are improved, but the ease of operation for battery exchange deteriorates
Solution Approach 1:
The work machine uses its own secondary battery and integrated removal system to remove and exchange the primary battery, making the system self-sufficient for battery exchange operations without requiring external equipment
Solution Approach 2:
A secondary battery serves as an intermediary power source to provide the energy needed for the battery removal system, enabling the exchange process without external equipment while maintaining the ability to handle heavy primary batteries
2Ease of operation
If additional external equipment is used to remove batteries, then the ease of operation for battery exchange is improved, but the device complexity and loss of time increase
Solution Approach 1:
The battery removal system is merged with the work machine itself, integrating the removal mechanism, secondary battery, and control systems into a unified system that eliminates the need for separate external equipment
Solution Approach 2:
The work machine is designed with multi-functionality, serving both as the work-performing device and as its own battery exchange system, allowing it to remove and replace batteries using its own resources
3Reliability
If the primary battery is removed when power level is low, then the reliability is improved, but the ease of operation deteriorates due to limited power availability
Solution Approach 1:
The system proactively monitors battery power levels and initiates the battery exchange process before complete depletion occurs, using the secondary battery to provide power for removal operations when the primary battery is still sufficient to support the exchange process
Solution Approach 2:
The secondary battery acts as an intermediary power source that can support the battery removal system when the primary battery power is low, ensuring reliable operation during the exchange process without requiring the primary battery to be fully charged
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 efficient battery exchange without the need for external equipment, maintaining machine functionality in low-power modes, reducing the risk of being stranded and optimizing battery life through smart power management.
Implementation Method 1
rotating a cammed lever on the frame to disconnect the first battery from the work machine
Data Source
AI summary
A system for disconnecting and connecting batteries on a work machine. The work machine has a prime battery, which may be supported by a specialized subframe on the frame of the work machine. The subframe has a cammed lever which provides ease of connection and disconnection of the prime battery. Once the prime battery is disconnected, an auxiliary battery operates the work machine in “limp mode”, or a reduced power setting, so that the prime battery can be placed for recharging. The auxiliary battery powers a system, which may be a stowed crane, a set of slides, or other mechanism, which removes the battery from the frame and places it away from the work machine, at a charging station or other location. A new, fully charged prime battery may then be placed into the subframe by the system, and connected through operation of the cammed lever.