Stamped Roller Connection for Stackable Trolley Chassis
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Solution Overview
Problem
The existing stackable trolleys require expensive forged components for connecting rollers to the chassis, which involves numerous post-processing steps and high manufacturing costs.
Innovation Solution
The use of molded parts, specifically stamped and bent components, eliminates the need for forged components by simplifying the connection process and reducing costs, while maintaining necessary manufacturing accuracy and stability through convex designs and precise alignment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If forged components are used for connecting rollers to the chassis, then the connection strength and stability are improved, but the manufacturing cost and complexity increase due to numerous post-processing steps
Solution Approach 1:
The patent changes the manufacturing method from forging to stamping and bending processes. The connection component is produced by stamping metal sheets and bending them into the required shape, which eliminates the need for expensive forging and post-processing while maintaining sufficient mechanical strength for the application
Solution Approach 2:
The patent adopts a cheaper stamped and bent metal component instead of an expensive forged component. The design accepts that the component may have limited service life but compensates through optimized geometry and material selection, achieving cost-effective production without sacrificing functional requirements
2Stability of the object's composition
If forged components are used for connecting rollers to the chassis, then the structural stability is improved, but the manufacturing precision and time consumption increase due to required post-processing steps
Solution Approach 1:
The patent changes the manufacturing process parameters from forging (high temperature, high pressure) to stamping and bending (room temperature, controlled force). This allows for precise dimensional control during the forming process itself, eliminating the need for subsequent machining or heat treatment to achieve required tolerances
Solution Approach 2:
The patent incorporates all necessary geometric features and structural characteristics directly into the stamping and bending process. The connection component is pre-formed with the exact shape and dimensions required, including any necessary reinforcements or attachment features, before assembly occurs
3Ease of manufacture
If stamped and bent parts are used instead of forged components, then the manufacturing cost and ease of production are improved, but the connection strength and stability may be compromised
Solution Approach 1:
The patent utilizes curved and bent geometries in the stamped connection component to distribute stresses more effectively. The bending process creates natural stress distribution patterns that can be optimized to enhance structural strength while maintaining the advantages of stamping production
Solution Approach 2:
The patent may combine the stamped metal connection component with other materials or structural elements to achieve the required strength. This could include using high-strength steel sheets, incorporating reinforcement ribs, or designing the connection to work in conjunction with other structural components of the trolley
4Productivity
If stamped and bent parts are used instead of forged components, then the productivity and output per unit time are improved, but the manufacturing precision and quality control become more challenging
Solution Approach 1:
The patent designs the stamping and bending process to produce the final component shape in one or few operations, with all critical dimensions and features established during forming. This preliminary action ensures consistent quality across production batches without requiring complex post-processing or inspection routines
Solution Approach 2:
The patent optimizes the stamping and bending process parameters (material selection, sheet thickness, forming forces, tooling design) to achieve the required precision consistently. By controlling these parameters during the high-speed stamping process, the patent maintains manufacturing quality while achieving high productivity
Data Source
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AI summary
The present invention relates to a stackable transport trolley (10) with a chassis (12), wherein the chassis (12) is equipped with rollers (14, 16), wherein at least one connection (20) is provided for attaching at least one roller (16) to the chassis (12), wherein the connection (20) comprises at least one stamped and bent part or stamped and embossed part (22).