Top-Accessible Caster Spring Adjustment Mechanism
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Solution Overview
Problem
Industrial caster assemblies require frequent adjustments for height and spring stiffness to accommodate varying operational conditions, such as moving pallets over uneven surfaces or high-speed turns, and current adjustment methods are cumbersome and time-consuming, often requiring the pallet truck to be taken out of operation.
Innovation Solution
A novel spring design where the spring assembly is located within the caster's main body, near the bearing axis, allowing for top-accessible torque adjustments using a torque wrench, enabling easy modification of spring deflection and height settings without the need to use shims or plates, and allowing for electronic or semi-automatic adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the spring assembly is located within the caster's main body near the bearing axis, then the adjustment accessibility is improved and device complexity is reduced, but the spring protection from environmental factors may be compromised
Solution Approach 1:
The spring assembly is nested within the caster housing, with the spring member positioned inside the spring assembly and the entire spring assembly contained within the caster housing. This nesting arrangement provides top-accessible torque adjustments while protecting the spring from environmental factors through the housing enclosure.
2Productivity
If top-accessible torque adjustments are implemented, then adjustment time is reduced and productivity is improved, but the device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The caster assembly allows operators to perform adjustments themselves using a torque wrench accessible from the top of the caster housing. The spring pre-deflection and caster height can be adjusted by the end user without requiring disassembly or specialized tools beyond a standard torque wrench, enabling quick field adjustments.
3Device complexity
If the spring assembly is integrated within the caster housing, then the overall device complexity is reduced and ease of manufacture is improved, but the adjustability range may be limited
Solution Approach 1:
The patent enables adjustment of spring pre-deflection and caster height parameters through torque applied to the spring assembly from the top. By varying the torque magnitude, operators can change the spring force and height settings to accommodate different operational conditions such as moving pallets over uneven surfaces versus high-speed turns on smooth floors.
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
This design enhances the flexibility and efficiency of caster assemblies by allowing for quick adjustments to spring force and height, reducing downtime and improving stability and speed during different operational scenarios, while protecting the spring from environmental factors.
Implementation Method 1
a spring member deformable along a top-to-bottom direction to dampen changes in a surface the caster wheel moves over and/or to dampen changes in load applied to the mounting plate
Implementation Method 2
a fitting adjustable relative to the spring assembly to pre-deflect the spring member in the spring space
Data Source
AI summary
A spring-force adjustable, height-adjustable industrial caster assembly including a mounting plate, a swivel housing that swivels relative to the mounting plate, and a spring assembly having components that are moveable relative to the swivel housing to controllably alter spring deflection and/or caster wheel height, which components can be adjusted by accessing the height-adjustable industrial caster assembly from above, eliminating the need to raise a pallet truck or other moveable assembly to which the caster assembly is coupled, away from the floor to be able to access and adjust the industrial caster assembly.