Historically, the manufacture of industrial casters has combined forging, casting, stamping, and welding processes. The key components in the manufacturing process have not changed, and some have developed changes in modern manufacturing technology. The forging and casting industry casters and key components of wheels have not changed significantly over the past 50 years. Many manufactured products in these processes of the same size and shape are completely unchanged. The part of the manufacturing industry that has significantly changed the casters is the manufacturing of the caster drilling platform, which is the body of the caster. In the past, RIGS were built with standard components of stamped parts, rotating parts of the forgings or welded to each other. Crafted using iron works to ModifyThe design of accessories such as brakes or toe guards, which are then welded to standard components.
Caster manufacturing to a new level has completely changed the motivation of caster manufacturing, and the following three aspects are the direction of improvement in production:
1) Increase intensity
2) Improve quality
3) Shorten the production time of the final product.
These improvements come from laser cutting and molding RIGS that remove about 40% of the welding, dramatically changing the design/build process. Let's briefly discuss these three key improvements.
1. Increased strength - The production of heavy castor legs connected to the platform is manufactured in a single slab blank. The blank is "developed" to accommodate the material that will be consumed when the upper leg is formed. The formation process, using a bending machine, moves the leg material in a 90 degree direction on a platform. In an "ixturing/welding process the legs will be welded to the platform in the traditional way. During the forming process, when completed, the bit error rate is 25%, which is better than welding the product and cannot fail unless there is a total major failure part. Laser cutting/forming process completely removes potential fault areas from finished products.
2. Improved quality - When parts are used in the stamping process, initially there is a clean material failure (about half the thickness of the material), the rest of the material will "escape", leaving an edge with a variation within the 0.03 inch range. When a part is laser-cut the edge quality and the hole (available for axles) can be kept at 0.002 inches. The most significant effect of such precision is in connection with the fact that the shaft, instead of grinding to the final size of the hole, is the ideal candidate for cutting the hole initially, significantly improving the quality of the final product.
3. Shorten the production cycle if the laser cutting/processing part is designed properly, which is the result of forming the process close to the time of the finished product being cut off. The reason for this is that essentially all components of the rig are integrated into the original laser for the blank, thus avoiding little or no additional welding. Avoiding secondary processing will be achieved by speeding up the product's manufacturing process while controlling additional costs.