Pivot Lever Battery Lock for Narrow-Aisle Forklifts
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Solution Overview
Problem
Electrically operated industrial trucks face prolonged downtime due to the time-consuming process of battery pack removal and replacement, which is cumbersome and limits the vehicle's capacity and efficiency, especially in narrow aisle logistics where quick refueling is not feasible.
Innovation Solution
A compact and ergonomic locking device with a pivot shaft and lever system that allows easy release and locking of the battery pack, minimizing component count and installation width, and incorporating clamping devices for secure positioning, enabling efficient battery pack removal and installation without compromising vehicle capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking device is used to secure the battery pack in the battery compartment, then the battery pack is held securely during operation, but the device complexity and number of components increase
Solution Approach 1:
The locking lever integrates multiple functions into a single component: it provides lateral support to the battery pack, engages with the release mechanism, and acts as a structural element of the locking device. This merging reduces the total number of components while maintaining secure holding capability.
Solution Approach 2:
The locking lever serves multiple purposes simultaneously: it is both a support element for the battery pack and a locking mechanism component, and also provides a interface for manual operation. This multi-functionality reduces device complexity while ensuring reliable securing.
2Reliability
If a locking device with manual lever operation is used, then the battery pack can be securely locked, but the ease of operation deteriorates due to tedious unplugging and attaching
Solution Approach 1:
The locking mechanism is designed to be automatically engaged when the battery pack is inserted into the battery compartment. The lever is spring-loaded or gravity-assisted to automatically move into the locked position, eliminating the need for manual plugging or complex operating procedures.
Solution Approach 2:
The manual lever operation is replaced with an automatic mechanical engagement system that uses the insertion motion itself to trigger the locking action, reducing the operational steps required and improving ease of use while maintaining secure locking.
3Reliability
If a locking device is installed in the battery compartment opening, then the battery pack can be locked, but the installation space in the width direction increases, reducing battery capacity
Solution Approach 1:
The locking device is positioned in the longitudinal direction of the vehicle rather than occupying width space. The locking lever extends along the longitudinal axis and engages with the battery pack in a way that utilizes the depth dimension instead of the width dimension, preserving maximum battery capacity.
Solution Approach 2:
The locking mechanism components are nested within the existing battery compartment structure, utilizing available space efficiently. The locking lever is positioned to engage with the battery pack body without requiring additional width, and the release mechanism is integrated into the existing frame structure.
4Reliability
If the locking device is positioned to span the battery compartment opening, then the battery pack can be locked, but the time required for battery pack exchange increases
Solution Approach 1:
The locking lever is pre-positioned and spring-loaded so that it automatically engages with the battery pack upon insertion. The release mechanism is pre-configured to allow quick disengagement, eliminating the need for time-consuming manual manipulation during battery pack exchange.
Solution Approach 2:
The locking mechanism is designed to engage and disengage in a single swift motion. The lever can be quickly moved between locked and unlocked positions, and the automatic engagement feature allows the locking action to occur during the insertion process itself, minimizing the time required for battery pack exchange.
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
The solution reduces downtime by simplifying battery pack exchange, maximizing battery capacity, and ensuring secure holding during operation, while being cost-effective and adaptable for narrow aisle trucks.
Implementation Method 1
a pivot lever (122) that is carried by the pivot shaft (126) and that moves between a locking position and a release position
Implementation Method 2
a pivot shaft that runs above the battery compartment in the width direction of the industrial truck and is pivotably supported by the bracket
Data Source
Figure 1~4
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to an electrically powered industrial truck, in particular a narrow-aisle forklift, comprising a battery compartment (112) for receiving a battery block (114), which is open on at least one side for removal of the battery block (114) in the width direction (B) of the vehicle and has a strut (116) extending substantially in the longitudinal direction (L) of the vehicle on its upper side, and at least one locking device (120) for the battery block (114) received in a battery compartment (112), wherein the at least one locking device (120) comprises a bracket (124) associated with the strut (116), a pivot shaft (126) extending above the battery compartment (112) in the width direction (B) of the industrial truck and pivotably mounted by the bracket (124), and a pivot lever (122) supported by the pivot shaft (126), which is pivotable between a locking position and a release position.wherein the pivot lever (122) is configured to support the battery block (114) in the lateral direction (B) of the vehicle in its locking position and to release the battery block (114) in the lateral direction (B) of the vehicle in its release position.