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In-depth analysis of key performance influencing factors of Dongguan Carsun caster wheel products
In industrial equipment, logistics and transportation, medical devices, and other fields, caster wheels serve as core auxiliary components, and their performance directly determines the equipment's operational efficiency, safety, and user experience. Dongguan carsun Caster Co., Ltd., a leading manufacturer of casters, focuses on the quality stability, load-bearing capacity, and steering flexibility of its industrial casters, Swivel Caster, and extra heavy duty casters. These are not only core indicators of product competitiveness but also crucial for earning customer trust. A thorough analysis of the key factors influencing these three key performance factors throughout the entire production process is of great practical significance for companies optimizing their production systems and improving product quality.
- Raw Materials: The "Foundation" of Product Performance
The quality of raw materials directly determines the inherent performance of casters Swivel Caster. The choice of raw materials for different components can have varying impacts on the quality, load-bearing capacity, and steering performance of the final product.
(1) Polyurethane wheels: Material purity and formula determine core performance
Polyurethane wheels are widely used in various scenarios due to their advantages such as wear resistance, shock absorption and quietness. Their performance depends entirely on the two core indicators of polyurethane materials:
Purity control: High-purity polyurethane raw materials do not contain impurities and have a more stable molecular structure. The wear resistance coefficient of the wheel body can be effectively improved, which can effectively resist the loss caused by frequent friction and significantly extend the service life. On the contrary, if recycled materials or impurities are mixed into the raw materials, the wheel body surface is prone to cracking and falling off, which not only shortens the service life but also affects the rolling stability due to the uneven surface.
Formula optimization: The formula ratio of polyurethane (hard segment and soft segment content, cross-linking agent addition amount, etc.) directly determines the hardness and elasticity of the wheel body.
When the wheel body is too hard due to imbalanced formula, the shock absorption performance will be greatly reduced. When driving on uneven ground, the vibration will be directly transmitted to the load-bearing object, which may cause damage to precision equipment; at the same time, the hard wheel body has a small contact area with the ground, which is prone to "stuck" when turning, reducing flexibility. When the wheel body is too soft due to imbalance in the formula, it is easy for the wheel body to be permanently deformed under load, and the load-bearing capacity is reduced, which cannot meet the load-bearing requirements of hundreds of kilograms in industrial scenarios. In addition, the rolling resistance of the deformed wheel body increases, which also affects the steering efficiency.
(2)Metal parts (brackets, bead plates): Steel quality determines load safety.
The metal parts of industrial casters and Swivel wheels, such as brackets and steering bead plates, are the core structures that bear weight. Their performance depends entirely on the quality of the steel: Advantages of high-quality steel: Use high-strength alloy steel or high-quality carbon steel (such as Q235A, 45# steel). This type of steel has good tensile strength and toughness. It is not easy to deform or bend when bearing rated weight or even short-term overload. Taking Carsun casters' super-heavy casters as an example, the brackets made of high-quality steel can stably bear 1-30 tons of weight and maintain structural stability during long-term use. Hidden dangers of inferior steel: If low-grade steel or recycled steel is used, there may be defects such as pores and cracks inside, and the strength and toughness are insufficient. In long-term high-load use, the brackets are prone to "fatigue deformation" and even break at the moment of turning or bearing weight, which not only causes the equipment to fail to operate normally, but also may cause safety accidents, seriously threatening the user's property and personnel safety.
- Production process: the "core link" that determines product quality
The production process runs through the entire process of caster Swivel wheels from raw materials to finished products. The process control accuracy of each link will have a "ripple effect" on the final performance of the product.
(1) Injection molding process: affecting the integrity and rolling performance of the wheel body
Polyurethane wheels, nylon wheels and other wheels are mostly made by injection molding process. The precise control of the three parameters of temperature, pressure and injection time is the key to avoiding wheel body defects:
Temperature control: If the injection molding machine barrel temperature is too high, the polyurethane raw materials will be prematurely cross-linked, resulting in "burned materials", and hard spots will appear inside the finished wheel body, which will produce abnormal noise when rolling; if the temperature is too low, the raw materials will not be fully melted, the fluidity is poor, and it will not be able to fill the mold cavity, resulting in depressions and missing materials on the wheel body surface, affecting the appearance, and reducing the load-bearing capacity due to incomplete structure.
Pressure and time control: If the injection molding pressure is insufficient or the holding time is too short, bubbles or shrinkage holes are easily formed inside the wheel body. Such hidden defects will lead to uneven strength of the wheel body structure. When the wheel is rolling under load, bubbles can easily become stress concentration points, which will cause cracks from the inside after long-term use, significantly shortening the life of the wheel. At the same time, the wheel with an uneven surface has unstable contact with the ground when rolling, which will directly reduce the steering sensitivity and cause "deviation".
(2)Welding process: determines the stability and steering accuracy of metal structures.
Most metal parts such as the brackets of industrial casters and Swivelwheels are connected by welding. The welding quality directly affects the overall structural strength and steering performance: Welding strength: If the welding current and voltage parameters are inappropriate, or the welder's operation is not standardized, it will cause problems such as "cold welds" and "slag inclusions" at the welding points. The tensile strength of such welds is lower than that of normal welds. When bearing weight or frequently turning, they are very easy to crack, which will cause the overall structure of the caster to fall apart, causing the risk of equipment tipping. Welding flatness: If sufficient grinding and leveling are not performed after welding, the welding parts will be bulged and deformed, resulting in uneven contact between the caster bracket and the wheel body and the ground. On the one hand, uneven force will reduce the upper limit of the caster's load capacity; on the other hand, the uneven structure will increase the friction resistance during turning, making the turning become stuck and affecting flexibility.
- Component Precision: Controlling the "Key Details" of Load and Steering
The caster is a system composed of multiple components such as the wheel body, bracket, bearing, steering mechanism, etc. The processing precision of each component directly determines the coordination of the system operation, which in turn affects the load-bearing capacity and steering sensitivity.
(1) Swivel caster steering mechanism: Matching precision determines steering stability
The core advantage of the Swivel wheel is flexible steering, and the precision of its steering mechanism is the key:The matching clearance is too large: If the matching clearance of the upper and lower bead plates in the steering part is too large, there will be obvious left and right shaking when turning. This will not only lead to a decrease in steering accuracy (unable to accurately control the direction of travel), but also cause the caster Swivel wheel to move due to slight external force when stationary, reducing the stability of the equipment; at the same time, shaking will cause the force point to change continuously, making it impossible to evenly bear the weight, indirectly reducing the load-bearing capacity.
The matching clearance is too small: If the matching clearance is too small, the friction resistance during steering will increase significantly, resulting in "heavy" steering and even "stuck" phenomenon. Long-term use will accelerate the wear of the steering shaft and steering bowl, forming a vicious cycle, which not only affects the user's operating experience, but also shortens the service life of the steering mechanism.
(2)Industrial casters bearings: Precision determines load uniformity and rolling smoothness.
Bearings are the core components connecting the wheel body and the bracket. Their precision directly affects the load capacity and rolling performance of the caster: Advantages of high-precision bearings: Using high-precision bearings can ensure the eccentricity of the wheel body during rolling, so that the wheel body is evenly stressed. Even under full load, the weight can be evenly transferred to the bracket through the bearing, thereby fully utilizing the designed load capacity of the caster. Problems of low-precision bearings: If ordinary bearings are used, their radial runout may exceed the rated value, causing the wheel body to "eccentric" when rolling. On the one hand, this will concentrate the weight on a part of the wheel body, reducing the upper limit of the load (the actual load capacity may deviate from the design value); on the other hand, eccentric rolling will produce irregular vibration and friction, resulting in uneven steering and even "wheel jumping", which seriously affects the user experience.
- Quality inspection: the "final checkpoint" to protect product quality
Even with strict control over raw materials, processes, precision and other aspects, defective products may still appear due to accidental factors. Comprehensive and strict quality inspection is the last line of defense to ensure that product performance meets the standards.
(1) Simulation scenario test: Accurately evaluate actual performance
Carsun casters must pass a series of tests that simulate actual use scenarios to verify product performance:
Static pressure test: Under a load of 1.2 times and 1.5 times the rated load, it is left to stand for more than 24 hours to observe whether the wheel body and bracket are deformed or cracked to ensure that the product can still stably bear loads under extreme working conditions.
Rolling life test: On a standard test platform, it is continuously rolled for more than 100,000 times at a set speed (such as 4km/h) to detect the degree of wheel wear and bearing lubrication status and evaluate the service life of the product.
Impact resistance test: Through the drop hammer impact test, the impact that the caster may be subjected to during transportation and installation is simulated to verify the impact resistance of the wheel body and bracket to avoid hidden damage caused by impact.
Brake life test: simulate real-world use scenarios, apply brake pressure (in both braking and releasing states) to verify the actual service life of the brakes. Avoid brake failure.
(2) Completeness of the inspection process: prevent defective products from entering the market
If there are loopholes in the quality inspection process (such as omitting certain types of tests, or sampling ratios being too low), defective products may enter the market:
Products that have not undergone load-bearing tests may suddenly break during use due to insufficient wheel strength;
Swivel wheels that have not undergone steering tests may affect equipment operation due to the jamming of the steering mechanism;
These problems will not only cause economic losses to users (such as equipment downtime and cargo damage), but will also seriously damage the brand reputation of Carsun Casters and affect its long-term market competitiveness.
To maintain its competitive edge in the industrial caster, swivel caster, and extra heavy duty caster markets, Dongguan Carsun Caster Co., Ltd. prioritizes "full-process quality control." For raw materials, the company selects high-purity polyurethane and high-quality steel to ensure performance from the source. In the production process, the company optimizes key processes like injection molding and welding to enhance product integrity and stability. For component precision, the company strictly controls steering mechanism clearances and bearing accuracy to ensure load-bearing and steering performance. Finally, the company implements comprehensive, comprehensive testing procedures to eliminate defective products. Through this multi-faceted collaborative effort, Carsun Caster continues to improve product quality, load-bearing capacity, and steering flexibility, meeting the needs of users across various industries and maintaining steady progress amidst fierce market competition.
Dongguan Carsun Caster Co.,Ltd
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We can produce different types of casters according to your requirements.
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Website:www.carsuncastor.com
Email: sales@casterchina.cc
Phone/WeChat/Skype:+86 18929102151
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www.carsuncastor.com
Factory address: No. 38 Industrial North Road,Shangjia Dazhou,Wanjiang Street,Dongguan city, Guangdong Province, China