Modular Forklift Battery-Counterweight Assembly for Flexible Power
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Solution Overview
Problem
Material handling vehicles require large batteries for extended power and counterbalancing, with existing systems lacking efficiency and flexibility in battery and counterweight integration.
Innovation Solution
A modular battery system comprising a battery assembly and a counterweight assembly with interchangeable interfaces, including roller bearings and non-metal slides, allowing for secure and adjustable attachment to the vehicle, enabling efficient power supply and counterbalancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If large batteries are used to provide extended power, then the power duration is improved, but the vehicle size and complexity increase
Solution Approach 1:
The battery system is divided into modular battery packs that can be independently installed and removed. Each battery pack is a self-contained unit with standardized interfaces, allowing the power system to be segmented into manageable modules rather than requiring a single large integrated battery system.
Solution Approach 2:
The battery packs are designed with universal interfaces that allow them to serve multiple functions: providing electrical power to the vehicle and simultaneously serving as counterweights for load balancing. This multi-functionality eliminates the need for separate counterweight components, reducing overall vehicle complexity.
2Duration of action of moving object
If large batteries are used for extended power, then the power duration is improved, but the vehicle physical size increases
Solution Approach 1:
The battery packs are designed to serve dual purposes: as power sources and as counterweights. By integrating the counterweight function into the battery packs themselves, the system eliminates the need for additional dedicated counterweight volume, thereby reducing overall vehicle size while maintaining extended power capability.
3Stability of the object's composition
If fixed battery-counterweight integration is used, then structural stability is improved, but adaptability decreases
Solution Approach 1:
The battery system is segmented into modular packs with standardized interfaces, allowing individual packs to be easily added, removed, or reconfigured. This segmentation maintains structural stability through standardized connection points while enabling high adaptability in terms of battery capacity selection and configuration flexibility.
Solution Approach 2:
The battery pack configuration is made dynamic and adjustable rather than fixed. Users can adapt the number and arrangement of battery packs based on specific operational requirements, allowing the system to dynamically adjust its power capacity and counterweight distribution while maintaining structural integrity through standardized interfaces.
4Ease of operation
If modular battery assembly with sliding engagement is used, then ease of installation is improved, but connection reliability may worsen
Solution Approach 1:
The connection system is segmented into discrete, standardized interface components with clear engagement features. This segmentation allows for simple sliding installation while incorporating built-in alignment and positioning mechanisms that ensure reliable connections without requiring complex fastening procedures.
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
Enhances the productivity and competitiveness of material handling vehicles by providing a flexible and efficient power and counterweight system that can be easily integrated and adjusted, improving operational efficiency.
Implementation Method 1
The roller bearing can be configured to provide a rolling interface between the battery attachment interface and the counterweight attachment interface
Implementation Method 2
at least one of the battery attachment interface and the counterweight attachment interface can include a non-metal slide, which can be configured to provide a sliding interface between the battery attachment interface and the counterweight attachment interface
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c~2d
AI summary
A modular battery system for use with a material handling vehicle, the modular battery system comprises a battery assembly and a counterweight assembly. The battery assembly can include a power source and a battery base, and the counterweight assembly can include a counterweight base configured to slidably receive the battery base and be removably secured thereto.