Swappable Battery Lift Assembly for Low-Downtime Power Machines
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Solution Overview
Problem
Conventional power machines require downtime for recharging depleted power sources, such as batteries, which can disrupt work operations and reduce efficiency.
Innovation Solution
A swappable power source system with a battery support assembly using a four-bar linkage and solenoid assemblies for precise mechanical and electrical connections, allowing quick exchange of power sources at designated stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power sources are recharged in place, then the power machine can maintain operational readiness, but work operations are disrupted and efficiency is reduced
Solution Approach 1:
The power source system is segmented into removable power source units that can be independently exchanged. The power source frame and support assembly are designed as separate, interchangeable components, allowing the depleted power source to be replaced with a charged one without affecting the main power machine structure or requiring in-place recharging operations.
Solution Approach 2:
Power sources are pre-charged at designated stations before being installed on the power machine. The support assembly positions the power source in advance for quick engagement, eliminating the need for time-consuming on-site recharging and enabling rapid replacement to maintain continuous operation.
2Loss of time
If power sources are exchanged frequently, then downtime is reduced and operational efficiency is enhanced, but the complexity of the support assembly and connection mechanisms increases
Solution Approach 1:
The support assembly and connection mechanisms are designed with universal features that accommodate repeated power source exchanges. The lift assembly, electrical connectors, and locking mechanisms are engineered to handle multiple engagement cycles with consistent positioning and connection, reducing the time penalty associated with frequent replacements despite the increased mechanical complexity.
Solution Approach 2:
The support assembly acts as an intermediary mechanism between the power machine and exchangeable power sources. It provides a standardized interface with automated positioning and connection features that simplify the exchange process, allowing complex functions to be encapsulated in a dedicated subsystem that can be optimized independently for rapid operation.
3Manufacturing precision
If a lift assembly with multiple positions is used, then precise positioning and alignment of power sources is achieved, but the mechanical complexity and number of components increases
Solution Approach 1:
The lift assembly employs dynamic positioning capabilities with multiple adjustable positions that allow the power source to be precisely aligned during the exchange process. The mechanism can move between raised, lowered, and intermediate positions to accommodate different alignment requirements, providing the flexibility needed for accurate mechanical and electrical connection while managing complexity through controlled degrees of freedom.
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
Enables continuous operation by allowing power sources to be exchanged quickly and efficiently, reducing downtime and enhancing operational efficiency and flexibility.
Implementation Method 1
A swappable power source system with a battery support assembly using a four-bar linkage and solenoid assemblies for precise mechanical and electrical connections
Implementation Method 2
A swappable power source system with a battery support assembly using a four-bar linkage and solenoid assemblies for precise mechanical and electrical connections
Data Source
AI summary
A power machine can include a power machine frame that supports one or more work elements, a battery support assembly, and a power source. The battery support assembly can include a lift assembly that is secured to the power machine frame and includes at least one movable link and a lift actuator, and a lift bracket that is movably supported relative to the power machine frame by the at least one movable link. The power source can include a power source frame that includes a support bracket and an electrical power source supported by the power source frame.