Universal Caster Yoke for Modular Brake Assembly Options
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Solution Overview
Problem
Existing caster assemblies require significant redesign and re-tooling to accommodate different functional capabilities, leading to high manufacturing costs and inefficiencies, as each configuration necessitates unique caster yokes and components, making it challenging to produce a range of models with varying functionalities.
Innovation Solution
A caster yoke design that allows for the selective mounting of various caster components, such as swivel brake lock, wheel brake lock, and trim cover assemblies, on a single unitary support frame, enabling different functional capabilities without altering the yoke's structure or components, thereby reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different caster configurations are designed with unique yokes and components, then each configuration can be optimized for its specific function, but manufacturing costs and complexity increase significantly due to redesign and re-tooling requirements
Solution Approach 1:
The caster yoke is designed as a universal platform that can accommodate multiple different caster components and configurations through standardized mounting interfaces. The same yoke structure can support wheel brake lock assemblies, swivel brake lock assemblies, or no brake assembly at all, allowing a single yoke design to serve multiple functional purposes across different caster models.
Solution Approach 2:
The brake lock assemblies are designed as separate, modular components that can be selectively mounted on the yoke rather than being integrated into the yoke structure itself. This segmentation allows the yoke to remain a simple, standardized support frame while the functional components are added or removed based on the desired caster configuration.
2Adaptability or versatility
If custom caster yokes are designed for each functional configuration, then specific functional requirements can be met, but manufacturing time and production efficiency decrease
Solution Approach 1:
A single universal yoke design serves as the base for multiple caster configurations. The yoke includes standardized mounting locations and interfaces that accommodate different brake lock assemblies and wheel arrangements, eliminating the need to manufacture custom yokes for each configuration and significantly improving production efficiency.
Solution Approach 2:
The caster system allows for dynamic configuration where brake lock assemblies can be selectively added or removed from the universal yoke based on the desired functional capability. This dynamic adaptability enables the same yoke to be used across different models without requiring redesign or re-tooling.
3Ease of manufacture
If a single universal yoke design is used for all configurations, then manufacturing costs and complexity are reduced, but the ability to meet specific functional requirements may be limited
Solution Approach 1:
The universal yoke incorporates standardized mounting interfaces and locations that are designed to accommodate multiple types of brake lock assemblies and wheel configurations. This universal design maintains manufacturing simplicity while enabling functional customization through the selective attachment of different components.
Solution Approach 2:
The yoke is pre-designed with standardized mounting locations, holes, and interfaces during the initial design phase that anticipate future attachment of various brake lock assemblies. This preliminary preparation of mounting features enables easy configuration customization without requiring modifications to the yoke structure itself.
Data Source
AI summary
A caster yoke for use in the manufacture of a set of wheeled caster assemblies wherein each caster assembly of the set of caster assemblies is capable of having unique functional capabilities relative to each other caster assembly of the set arising from different combinations of caster components (selected from a set of pre-determined of caster components) being mountable on each respective caster yoke of the set of wheeled caster assemblies. To this end, the caster yoke is provided with all of the mounting features necessary to selectively mount all of the respective caster components of the pre-determined set on the caster yoke, such that the same form of caster yoke may be used without modification as a mounting frame to create a set of caster assemblies having different functionalities, significantly reducing design, production and inventory costs for the set of caster assemblies.