Stackable Battery Pack Rack for Transport and Installation
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Solution Overview
Problem
The existing methods for installing and transporting battery packs, such as NaS batteries, require costly and time-consuming steel-framed installation racks and dedicated tools, with unnecessary transportation racks becoming a financial burden after installation.
Innovation Solution
A rack design featuring a bottom frame with struts and tapered fitting projections allows for stacking and reuse as both transportation and installation racks, eliminating the need for separate installation racks and dedicated tools, with optional load distribution plates and spacers for safe handling and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate steel-framed installation racks are constructed, then the battery modules can be installed in a large facility, but the construction requires many days and much cost
Solution Approach 1:
The patent merges the transportation rack and installation rack into a single integrated structure. The transportation rack is designed with stacking capabilities that allow it to function directly as an installation rack, eliminating the need for separate construction of installation racks. This is achieved through the strut structure with fitting projections and holes that enable vertical stacking of multiple racks to form a multi-tier battery module installation structure.
Solution Approach 2:
The transportation rack is designed to serve multiple functions: it can transport battery modules individually and can be stacked to form installation racks for large facilities. The universal design allows the same rack structure to be used for both transportation and installation purposes, reducing the need for specialized equipment and reducing overall project cost and time.
2Ease of operation
If dedicated tools with hoisting and push-in functions are used for installation, then battery modules can be installed efficiently, but the tools are not necessary after installation causing waste in cost
Solution Approach 1:
The rack structure provides self-service capabilities through its built-in fitting projections and holes that enable direct stacking and interlocking of racks. The design allows for easy assembly and disassembly using simple forklift operations without requiring complex dedicated installation tools. The structural features of the struts and fitting mechanisms enable the system to be installed and configured by the users themselves with minimal specialized equipment.
3Reliability
If transportation racks with sufficient strength are used to avoid troubles during transportation, then battery modules can be shipped safely, but the racks become unnecessary after installation involving scrapping or returning cost
Solution Approach 1:
The patent enables recovery and reuse of the transportation racks by designing them with stacking capabilities. Instead of discarding or returning the racks after transportation, they can be stacked vertically to form installation structures for battery modules. The fitting projections and holes in the struts allow multiple racks to be interconnected, transforming the transportation racks into permanent installation infrastructure and eliminating disposal costs.
4Productivity
If separate installation racks are constructed, then battery modules can be installed in large facilities, but the manufacturing cost of installation racks increases
Solution Approach 1:
The patent segments the installation structure into multiple standardized rack units that can be manufactured independently and then stacked to form the complete installation system. Each rack unit is a self-contained module with standardized struts and fitting features, allowing for economical manufacturing through repetition and standardization. This modular approach reduces the overall manufacturing cost compared to constructing a single large custom installation rack.
Data Source
AI summary
A rack for battery packs for transporting battery modules which are stored therein, and includes a bottom frame and struts located at four corners of the bottom frame. A fitting projection is formed at an upper end of each of the struts, a fitting hole into which the fitting projection is fitted is formed in a bottom part of each of the struts. When the rack is stacked one on top of another by fitting the fitting projection of each of the struts of a lower rack into the projection hole of each of the struts of an upper rack, the rack for battery pack can be used as an installation rack. Accordingly, a separate installation rack is not necessary, and returning a transportation rack is not necessary, either.