Modular Work Cart Charging Module with Removable Clamp
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Solution Overview
Problem
Existing work cart charging systems are not efficiently designed to accommodate multiple battery types and provide secure, compact, and versatile charging solutions, limiting their usability and convenience.
Innovation Solution
A modular charging module system that can be removably coupled to a mobile work cart, featuring a compact design with multiple charging bays, secure mounting options, and integrated features like magnetic adhesion, pivotable shelves, and lock mechanisms, allowing for easy access and secure storage of battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a charging module is designed to accommodate multiple battery types with secure mounting, then battery pack security and versatility are improved, but the device complexity and footprint increase
Solution Approach 1:
The charging module employs a universal charging bay design with adjustable clamps and multiple mounting configurations that can accommodate various battery pack types and sizes. The clamp mechanism can be positioned at different locations along the charging bay, and the module can be mounted in multiple orientations (horizontal, vertical, angled) to work with different battery configurations, thereby achieving multi-functionality without requiring separate charging devices for each battery type.
Solution Approach 2:
The charging module is designed as a separable, modular system where the charging bay, clamp mechanism, and mounting features can be independently configured. The clamp is a separate component that can be repositioned along the charging bay, and the entire charging module can be removed from the work cart and used independently, allowing flexible adaptation to different battery types without redesigning the entire system.
2Reliability
If a clamp mechanism is added to securely hold battery packs, then battery pack security is improved, but the device complexity increases
Solution Approach 1:
The clamp mechanism is designed to be movable and adjustable along the charging bay rather than fixed in a single position. This dynamic positioning capability allows the clamp to adapt to different battery pack sizes and shapes while maintaining secure retention. The spring-loaded or adjustable nature of the clamp provides consistent holding force across various battery configurations without requiring multiple fixed clamp positions.
3Ease of operation
If multiple mounting options are provided for the charging module, then ease of installation and versatility are improved, but the device complexity increases
Solution Approach 1:
The charging module incorporates multiple mounting features including clamps, cleats, and recesses that enable the same module to be installed in various configurations (horizontal, vertical, angled) and locations on the work cart. This universal mounting capability allows a single charging module design to serve multiple installation scenarios without requiring different mounting hardware for each configuration.
4Ease of operation
If the charging module is designed to be removable from the work cart, then ease of operation and portability are improved, but the reliability of connection may worsen
Solution Approach 1:
The charging module employs a dynamic mounting system with clamps and cleats that can be quickly engaged and disengaged from the work cart. The clamp mechanism provides secure attachment when installed, ensuring reliable connection during use, while the same mechanism allows for quick removal when needed. The spring-loaded or adjustable clamp design maintains consistent holding force whether the module is attached to the cart or used independently.
Data Source
AI summary
A charging module is configured to be removably coupled to a mobile work cart. The charging module includes a housing having a first end, a second end, a front side, and a rear side. The housing defines a cavity in the front side and includes a charging bay located within the cavity. The charging bay is configured to removably receive a battery pack to electrically connect the battery pack to the charging module. The charging module also includes a clamp coupled to the rear side of the housing. The clamp includes a handle portion and an arm. The clamp is movable relative to the housing between a deployed position and a retracted position. The clamp is biased toward the retracted position. The housing defines a recess in the rear side. When the clamp is in the retracted position the arm is received within the recess.