Stackable Battery Rack Structure for Tool-Free Installation
Find Innovative SolutionsGenerate Solutions
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, leading to unnecessary expenses and inefficiencies, including the need for scrapping or returning transportation racks after installation.
Innovation Solution
A rack system with a bottom frame and corner struts featuring fitting projections and holes allows for stacking and reuse of transportation racks as installation racks, eliminating the need for separate installation racks and dedicated tools, and includes a plate-like member for load distribution and a spacer for adjusting height during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a steel-framed installation rack is constructed to store several dozens of battery modules, then the battery modules can be securely stored and installed, but it requires many days and much cost for construction
Solution Approach 1:
The installation rack is divided into multiple individual racks, each capable of storing a specific number of battery modules. These segmented racks can be independently assembled and then combined, significantly reducing construction time while maintaining the overall storage capacity and structural reliability needed for securing dozens of battery modules.
Solution Approach 2:
Multiple individual racks are combined together to form a complete installation system. Each rack is designed with stacking capabilities through fitting projections and holes, allowing them to be merged vertically and horizontally. This combining approach enables rapid assembly of a large-scale installation rack system without requiring extensive construction time.
2Ease of operation
If a dedicated tool with hoisting and push-in function is used to install battery modules, then the installation can be performed, but it causes a waste in cost since the tool is not necessary after completion
Solution Approach 1:
The rack structure itself is designed to serve multiple functions: it provides structural support for battery modules, enables stacking for vertical storage, and incorporates built-in hoisting and positioning capabilities through its fitting projection and hole system. This eliminates the need for separate dedicated installation tools, as the rack performs both storage and installation functions.
Solution Approach 2:
The rack structure is designed to be self-sufficient for installation operations. The fitting projections and holes enable the rack to hoist and position battery modules without requiring external dedicated tools. The system installs itself using its own structural features, eliminating the need for costly specialized equipment that would otherwise be discarded after installation.
3Reliability
If a steel-framed transportation rack with sufficient strength is used to avoid troubles during transportation, then the battery modules are protected during shipping, but it becomes unnecessary after installation and involves a lot of cost for scrapping or returning
Solution Approach 1:
The rack is designed as a multi-functional unit that serves both as a transportation container and an installation rack. The same steel-framed structure with sufficient strength for safe transportation becomes the permanent installation framework after the battery modules are transferred. This dual functionality eliminates the need for separate transportation and installation racks, avoiding the costs associated with scrapping or returning empty transportation racks.
Solution Approach 2:
Instead of discarding the transportation rack after use, the design enables recovery and reuse of the same rack structure for installation purposes. The rack transitions from a temporary transportation container to a permanent installation framework, maximizing the utilization of the invested resources and eliminating waste associated with scrapping or returning the transportation rack.
4Adaptability or versatility
If separate transportation rack and installation rack are used, then transportation and installation functions are fulfilled, but it increases the overall cost and complexity
Solution Approach 1:
The rack is designed as a universal system that fulfills both transportation and installation functions. The same rack structure with appropriate strength and configuration serves as the transportation container during shipping and then becomes the installation framework at the destination. This eliminates the need for separate transportation and installation racks, reducing overall system complexity and the number of components required.
Solution Approach 2:
The transportation and installation rack functions are merged into a single unified rack system. The rack is designed with features that satisfy both transportation requirements (strength, stability) and installation requirements (stacking capability, module positioning). This merging of functions reduces the total number of racks needed and simplifies the overall system while maintaining adaptability for both purposes.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A rack for battery packs is provided, according to which a cost for manufacturing an installation rack can be reduced, a cost required for scrapping or returning a transportation rack can be reduced, and installation is made possible without using a dedicated tool. The rack for battery pack according to the present invention is a rack for transporting battery modules 1 which are stored therein, and includes a bottom frame 2 and struts 3 located at four corners of the bottom frame 2. A fitting projection 5 is formed at an upper end of each of the struts 3, a fitting hole 9 into which the fitting projection 5 is fitted is formed in a bottom part of each of the struts 3. When the rack is stacked one on top of another by fitting the fitting projection 5 of each of the struts 3 of a lower rack into the projection hole 9 of each of the struts 3 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.