Caster Brake Mechanism with Wire-Actuated Lever Lock
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Solution Overview
Problem
Conventional casters with hand-operated brakes require strong force for locking, are complex and costly, and are inconvenient to use, while foot-operated casters are difficult to operate and can damage shoes, with individual tire locking requiring multiple operations.
Innovation Solution
A caster system with a wheel, fork, and brake pin, utilizing a connection wire and spring mechanism with a controller that includes a rotation knob or handle, double crank, and links to transmit braking force with a lever action, allowing for single operation locking of wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hand brake mechanisms are applied to bag casters, then braking function is achieved, but the structure becomes complex and large
Solution Approach 1:
The brake mechanism is segmented into independent functional components: a brake arm for applying braking force, a connection rod for force transmission, and a controller with crank mechanism for operation. This segmentation allows each component to be optimized independently and simplifies the overall structure by eliminating unnecessary integrated parts.
Solution Approach 2:
The brake mechanism is extracted as a separate functional module from the caster assembly, with the brake arm, connection rod, and controller forming an independent braking subsystem. This extraction simplifies the main caster structure while maintaining complete braking functionality through the dedicated brake components.
2Reliability
If conventional hand brake mechanisms are applied to bag casters, then braking function is achieved, but the cost increases
Solution Approach 1:
The brake mechanism uses simple, inexpensive components such as a thin plate brake arm, a straightforward connection rod, and a basic crank-based controller. These components are designed to be economical to manufacture while providing sufficient braking function, avoiding the use of expensive materials or complex machining processes.
Solution Approach 2:
Instead of using a complex mechanical linkage system to transmit braking force, the invention inverts the approach by using a flexible connection rod that transmits force through bending and flexing. This inverted approach to force transmission simplifies manufacturing while maintaining braking effectiveness.
3Reliability
If conventional hand brake mechanisms are applied to bag casters, then braking function is achieved, but operation becomes difficult requiring strong force
Solution Approach 1:
The controller incorporates a crank mechanism with rotational motion that converts small hand forces into larger braking forces through the curved path of the crank arm. This curvature-based mechanical advantage allows easy operation with minimal hand force while achieving reliable wheel locking.
Solution Approach 2:
The brake arm is designed as a flexible thin plate that dynamically bends and flexes during operation, allowing the mechanism to adapt to varying braking forces. This dynamic flexibility enables the brake to engage smoothly with varying force requirements, making operation easier while maintaining reliable braking function.
4Reliability
If conventional hand brake mechanisms are applied to bag casters, then braking function is achieved, but the bag becomes heavy
Solution Approach 1:
The brake arm is constructed as a thin plate rather than a solid mechanical component, significantly reducing its weight while maintaining sufficient structural strength for braking function. This thin-film approach to brake component design minimizes the added weight to the bag while preserving reliable wheel locking capability.
Solution Approach 2:
The braking system is segmented into minimal essential components (brake arm, connection rod, controller) without unnecessary structural elements. This segmentation eliminates excess weight from non-essential parts while maintaining complete braking functionality through the streamlined component set.
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
The system is made small-sized, lightweight, and low-cost, enabling convenient operation with the ability to lock multiple wheels with a single action, reducing the complexity and cost of the locking mechanism.
Implementation Method 1
enforced by a spring
Implementation Method 2
brake driver transmits the braking force of the connection wire to the brake pin magnified with lever action
Implementation Method 3
brake pin for stopping rotation of the wheel
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(h)
Figure 3(a)~3(f)
AI summary
Provided is a caster system equipped with hand-operated brakes. The caster system is easy to use while being compact, lightweight, and low-cost. Wheel 2 comprises a tire 1 and a rim 16. A fork 3 supports the rotating wheel 2 via an axle 15. A base 4 mounted on a bag supports the swinging fork 3. A hollow swing shaft 14 is mounted on a bearing 12 in the base 4. A wire 7 for transmitting force is pulled by means of a rotation knob 13 in a controller located away from the wheel 2. Force is applied by a spring to the wire 7 in the opening direction. Therefore, if the rotation knob is rotated by an angle not smaller than a predetermined value, rotational moment is applied in the reverse direction, resulting in the rotation knob 13 being locked. Force is transmitted to a lever 18 via the wire 7. The force of the wire 7 is magnified by the action of the lever 18, and the resulting force pushes a brake pin 5 that is located inside the swing shaft 14 in the fork 3. The brake pin 5 abuts the tire 1 with the result that frictional resistance prevents rotation of the wheel 2.