What are the key quality control points in the production process of brake casters?

Key quality control points in the production process of brake casters are listed below.
The production quality of brake casters directly impacts their braking safety, durability, and operational stability. The following key aspects require focused control during the production process:

1. Raw Material Quality Control
Material Compliance: Strictly inspect the friction coefficient, temperature resistance, and wear resistance of brake pads (e.g., rubber, PU), and the tensile strength and anti-corrosion coating thickness of metal brackets (e.g., steel, cast iron) to ensure that the materials meet design standards (e.g., EN 12530 and GB/T 14687-2011 material requirements).

Component Precision: Check the dimensional tolerances (e.g., shaft diameter deviation ≤ 0.02mm) and surface finish of core components such as bearings, springs, and bushings to prevent post-assembly seizure or brake failure due to substandard components.

2. Brake Mechanism Assembly Accuracy
Brake assembly fit: Ensure the brake pads and wheel contact surfaces are fully aligned, with a clearance of ≤0.1mm to prevent uneven force and slippage. For full-brake casters, check the alignment accuracy of the steering bracket and wheel locking mechanism to ensure synchronized braking without any lag.

Pedal and spring tension calibration: Foot-operated brake pedal travel must be uniform (e.g., standard travel 15-20mm). Spring tension must pass a tensile test (e.g., spring force tolerance ≤5%) to ensure instant braking and smooth release. Avoid operating failures caused by excessive looseness or tightness.

3. Load and Braking Performance Testing
Static load test: Test the brakes for 24 hours at 1.25 times the rated load. Inspect the wheel, bracket, and brake components for deformation (e.g., bracket bending ≤0.5mm) to ensure there is no structural damage. Braking Performance Verification: Apply a standard horizontal tensile force (e.g., 15% of the load) to test whether the wheel slips after the brake is locked. For full-brake models, the steering lock must also be verified to ensure no wheel rotation or bracket deflection.

4. Durability and Environmental Adaptability Testing
Fatigue Life Testing: Subject the brake pedal to thousands of pedal cycles (e.g., 5,000 or more as required by EN 12530). After completion, check for brake pad wear (≤0.5mm) and spring elasticity loss (≤10%) to ensure stable braking performance after long-term use.

Environmental Tolerance Testing: Test the brake components for 48 hours in a high- and low-temperature (-20°C to 60°C), humid (90% humidity), and oily environments to verify reliability under extreme operating conditions.

5. Appearance and Detailed Workmanship Inspection
Structural Integrity: Welding points (such as bracket welds) are inspected for cold welds and cracks, and screw tightening torque is in compliance (e.g., 8-10 N·m for M8 screws) to prevent loosening during use.

Surface Finish Quality: Metal parts are coated with anti-corrosion coatings with no missing coatings or bulges, and the wheel surface is free of bubbles and scratches, ensuring aesthetics and corrosion resistance.

6. Factory Inspection and Traceability Records
Batch Sampling Inspection: 5%-10% of each batch is sampled and repeatedly tested for load, braking, and durability. Unqualified batches require full inspection and rework.

Data Traceability and Archiving: Raw material batches, assembly parameters, test data, and inspector information are recorded to establish a product traceability system to facilitate subsequent tracing and improvement of quality issues.

Strict control of these key points effectively reduces safety risks associated with brake casters caused by material defects, assembly errors, or substandard performance, ensuring product compliance with industry standards and usage requirements.