Power Unit Replacement System for Work Machines
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Solution Overview
Problem
Existing battery swap systems for electric drive work machines, such as those used in mining, face challenges with swinging and tipping of battery packs during lifting and lowering, leading to potential damage and inefficiencies in tight spaces.
Innovation Solution
A power unit replacement system that includes a lift system with a lift arm and a roller, and a power unit housing with an engagement element and a cam element, which work together to maintain the power unit in an upright and level orientation during replacement, preventing swinging and tipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lift arm connects near the top of the battery pack above the center-of-gravity, then the battery pack can be lifted off the work machine, but the bottom of the battery pack swings inward during lifting causing impact damage
Solution Approach 1:
A cam element is introduced as an intermediary between the lift arm and the battery pack housing. The cam element converts the rotational motion of the lift arm into controlled linear motion that guides the battery pack vertically without swinging, thereby preventing impact damage while maintaining ease of operation
Solution Approach 2:
The cam element utilizes a curved surface profile that guides the battery pack along a controlled path during lifting. The curved geometry ensures the battery pack moves vertically without swinging inward, eliminating the harmful impact effect while maintaining operational ease
2Productivity
If the battery pack is lowered to the ground surface, then the battery pack can be replaced, but the tilted orientation from swinging causes the battery pack to tip over and damage itself
Solution Approach 1:
The cam element acts as a guiding intermediary during the lowering process, ensuring the battery pack maintains a vertical orientation throughout the movement. This prevents tipping over when the battery pack is set down, maintaining both productivity and reliability
Solution Approach 2:
The curved profile of the cam element guides the battery pack along a controlled vertical path during lowering. This curved guidance path prevents tilted orientation and ensures the battery pack remains stable and upright when placed on the ground surface
3Ease of operation
If a horizontal battery replacement procedure is used, then the battery can be replaced, but additional space is required which is not available in tight mining spaces
Solution Approach 1:
The system transitions from horizontal battery replacement to vertical lifting and lowering. By utilizing the vertical dimension through the lift arm and cam element mechanism, the system achieves battery replacement in a compact footprint suitable for tight mining spaces while maintaining ease of operation
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 system effectively reduces damage to the power unit and the work machine by maintaining the power unit in a stable orientation during replacement, facilitating efficient and fast power unit replacement, and enabling operation in tight spaces.
Implementation Method 1
a cam element, projecting from the power unit housing, configured to slidably engage with the roller during actuation of the lift arm
Data Source
AI summary
A machine may include a frame and a lift system. The lift system may include a lift arm attached to the frame. The lift arm may be configured to actuate between a raised position and a lowered position. The lift system may include a roller attached to the frame. The machine may include a power unit including an energy storage unit and a power unit housing containing the energy storage unit. The power unit housing may include an engagement element configured to engage the power unit housing with the lift arm. The power unit housing may include a cam element, projecting from the power unit housing, configured to slidably engage with the roller during actuation of the lift arm.