Sinusoidal Caster Wheels for Lower Rolling and Swivel Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional casters with cylindrical wheels experience significant resistance when rolling and swiveling, especially under heavy loads, due to their flat profile and cylindrical shape, which increases friction and wear.
Innovation Solution
The use of sinusoidal wheels with a rim center that follows a sinusoidal pattern around the circumference, configured at an offset angle, reduces rolling resistance and allows for easier swiveling by distributing the load more efficiently and minimizing frictional contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cylindrical wheels are used, then the structure is simple and easy to manufacture, but rolling resistance increases significantly under heavy loads
Solution Approach 1:
The patent applies curvature by transitioning from a flat cylindrical wheel profile to a sinusoidal profile. The sinusoidal shape creates a curved, undulating surface that reduces the contact area with the ground and minimizes the deformation required during rolling, thereby reducing rolling resistance while maintaining manufacturing feasibility through standard molding or machining processes.
Solution Approach 2:
The patent changes the geometric parameters of the wheel by introducing a sinusoidal profile defined by specific amplitude and frequency parameters. This parameter change transforms the wheel's interaction with the ground, allowing it to roll more efficiently under load by continuously adjusting the contact point and reducing energy loss to deformation.
2Device complexity
If conventional cylindrical wheels with flat profile are used, then the wheel structure is simple, but frictional resistance during swiveling increases significantly
Solution Approach 1:
The sinusoidal profile creates a curved surface that reduces the frictional contact area during swiveling motion. As the wheel pivots, the curved profile allows for more efficient rotation by minimizing the scrubbing action between the wheel and ground, thereby reducing frictional resistance and wear during directional changes.
3Force
If sinusoidal wheels are used, then rolling resistance is reduced by 57%, but the wheel shape becomes more complex
Solution Approach 1:
The sinusoidal profile is a mathematically defined curved shape that can be efficiently manufactured using modern molding or machining techniques. The curvature provides the mechanical advantage of reduced rolling resistance while the regular, repeating pattern of the sine wave allows for standardized production processes that mitigate the complexity issue.
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 sinusoidal wheels provide 57% less rolling resistance compared to conventional cylindrical wheels, enabling easier movement of heavy loads and improved maneuverability by reducing the force required to pivot and change direction.
Implementation Method 1
the flat profile of a standard cylindrical wheel may result in a significant amount of frictional resistance being exerted on said wheel while being swiveled
Implementation Method 2
a plurality of ball bearings configured to be engaged with the pivot shaft
Data Source
AI summary
A caster assembly having a top cap configured to engage with a structure, a caster leg configured to pivotally engage with the top cap, such that the caster leg selectively pivots about a pivot axis, and a pair of sinusoidal wheels configured to be rotationally engaged with the caster leg, the sinusoidal wheels being configured to rotate about a wheel rotational axis and swivel with the caster leg as a required when the structure is moved. An angled member of the caster leg may be configured to engage with the sinusoidal wheels such that the wheel rotational axis is not intersected by the pivot axis. An offset angle formed between the angled member and a vertical member of the caster leg, when used in conjunction with the disclosed sinusoidal wheels, is configured to ease structure movement by minimizing resistances exerted on the sinusoidal wheels during rolling and caster leg pivoting.