Toggle Lever Locking Device for Ergonomic Battery Replacement
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Solution Overview
Problem
Existing lifting trucks with locking devices for battery blocks require complex operations and tools for battery replacement, and are not compatible with unmodified standard batteries.
Innovation Solution
A locking device with a toggle lever mechanism, where a first lever is swivel-mounted on the vehicle frame and a second lever with a buffer is coupled to clamp or release the battery block, allowing for ergonomic and tool-free battery replacement using unmodified standard batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a locking device with toggle lever mechanism and buffer is used, then battery replacement becomes fast and ergonomic without tools, but the device complexity increases compared to simple locking mechanisms
Solution Approach 1:
The second lever is mounted on the first lever, creating a nested configuration where the locking portion is coupled to the first lever and the second lever is coupled to the first lever. This nested arrangement allows the toggle mechanism to achieve strong clamping force while maintaining a compact structure that doesn't excessively increase device complexity.
Solution Approach 2:
The buffer acts as an intermediary element between the locking portion and the battery block. It mediates the clamping force by pressing the front wall of the battery block against the stop surface, providing ergonomic operation without requiring direct mechanical contact that would increase complexity.
2Reliability
If the locking device uses a toggle lever lock mechanism, then the battery block is securely clamped, but the operation requires multiple pivot positions and becomes more complex
Solution Approach 1:
The locking device is segmented into two separate levers: the first lever provides the primary pivoting motion mounted on the bracket component, while the second lever mounted on the first lever provides the clamping action. This segmentation allows each lever to have a simpler, more focused function rather than requiring one complex lever to perform all functions.
Solution Approach 2:
The second lever is nested on the first lever, creating a hierarchical structure where the first lever's pivot provides the primary motion and the second lever's locking portion provides the secure clamping. This nested arrangement achieves reliable clamping while simplifying the operational sequence compared to a single complex lever system.
3Adaptability or versatility
If the locking portion receives the inner side wall of the battery block, then unmodified standard batteries can be used, but the locking force may be insufficient without additional buffering
Solution Approach 1:
The buffer serves as an intermediary that amplifies and distributes the clamping force. When the locking portion engages the front wall of the battery block, the buffer presses this wall against the stop surface with sufficient force to secure standard batteries, converting the moderate mechanical engagement into effective clamping force.
Solution Approach 2:
The buffer changes the force transmission parameter by introducing elastic deformation and distributed pressure. Instead of relying solely on rigid mechanical engagement, the buffer's elastic properties allow it to maintain consistent clamping force across variations in battery dimensions, ensuring compatibility with unmodified standard batteries while providing sufficient holding force.
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 fast, simple, and ergonomic battery replacement without the need for tools, using unmodified standard batteries, by engaging or disengaging the buffer with the battery block's inner side wall, allowing horizontal movement and compatibility with standard battery designs.
Implementation Method 1
The locking portion has at least one buffer made of an elastomer material. In the locked position, the buffer connects to the inside of the front wall and holds the front wall of the battery block against the stop surface in the bracket component.
Data Source
AI summary
A lifting truck, in the frame of which a battery mount is arranged, wherein a locking device is provided, which locks in a releasable manner the battery block in the installed state with respect to the frame or a battery mount, wherein the locking device has a first lever and a second lever. The second lever works with at least one buffer on an inside wall of the battery block to clamp it against a stop.