Rotatable Steel Wire Handle for Heavy Battery Packs
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Solution Overview
Problem
Larger and heavier battery packs, such as the 72V dual-parallel battery pack, become laborious to handle due to increased weight and height, causing a poor user experience, especially for individuals with smaller hands, and existing solutions like handles on battery packs are complex, low in strength, and large in size.
Innovation Solution
A battery pack with a rotatably connected handle integrally formed by a steel wire, featuring mounting holes, recessed portions, and buckles, allowing the handle to be easily attached and detached, providing high strength and small size, and a rubber coating for impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a handle is added to the battery pack to improve carrying ease, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The handle is designed as a separate, rotatably connected component that can be independently attached to the battery pack body. This segmentation allows the handle to be added only when needed for carrying, without permanently complicating the battery pack structure. The handle connects via simple mounting holes and buckles, maintaining structural simplicity while providing ease of operation when required.
2Ease of manufacture
If a plastic handle is used to reduce manufacturing complexity, then ease of manufacture is improved, but strength decreases
Solution Approach 1:
The handle is constructed from steel wire, which provides high strength and durability. The steel wire is bent and formed into the handle shape, then secured to the battery pack with buckles. This material choice ensures the handle can support the weight of heavier battery packs while remaining manufacturable through standard metal forming processes.
3Ease of operation
If the handle is always extended to improve carrying ease, then ease of operation is improved, but volume increases
Solution Approach 1:
The handle is designed to be rotatable and can be positioned in different states - extended for carrying or retracted against the battery pack body when not in use. This dynamic positioning allows the handle to provide carrying assistance when needed while minimizing the occupied volume during storage or transport, effectively resolving the volume contradiction.
4Strength
If a steel wire handle is used to increase strength, then strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The steel wire handle is formed by bending and shaping the wire into the desired configuration, then securing it with buckles that allow for easy attachment and detachment. This approach maintains the high strength of steel while using simple forming operations and mechanical fastening that are easy to manufacture and assemble, resolving the contradiction between strength and ease of manufacture.
Data Source
AI summary
A battery pack includes a main body, and a handle rotatably connected to the main body. The handle is integrally formed by a steel wire. A related garden tool includes a working head, a power driving device for driving the working head to work, and the battery pack.