What safety issues may arise from wear on the connecting shaft between the brake lever and the bracket?

The shaft connecting the brake lever and the bracket is the core transmission component of the caster brake system. Wear can undermine system stability and reliability, leading to serious safety issues:

Brake failure or delay: Wear increases play and reduces transmission accuracy. Braking may occur when the brake lever is fully engaged but the wheel is not locked, or the brake may lag. In emergency situations (such as near people or steps), the equipment may not stop in time, increasing the risk of a collision.

Sudden and complete failure: Severe wear (such as undersized shaft diameter or cracks) can cause the shaft to suddenly break or fall off during braking, completely defeating the brake system and allowing the wheels to spin freely. This can cause the load-carrying equipment to slide uncontrollably on slopes or slippery surfaces, resulting in damage to the equipment, falling cargo, and casualties.

Equipment drift or rollover: Wear can cause wobbling or jamming, potentially resulting in uneven braking force on both sides of multi-wheeled equipment. This can cause the equipment to drift to one side during braking. Equipment with a high center of gravity (such as high-rise carts and racks) is prone to rollover. In confined spaces or high-rise locations, drift can easily lead to secondary accidents such as collisions with guardrails and walls.

Unexpected Operational Jamming: Uneven wear clearances can cause the brake lever to jam when lifted or pressed (e.g., stuck in a semi-braked position). The wheels can neither rotate freely nor lock, causing the equipment to move erratically and jerkily, making it difficult to control. Jamming during movement can easily cause the operator to fall or the equipment to lose control and crash.

Acceleration System Damage (Vicious Cycle): The vibration and noise caused by wear exacerbate abnormal friction in components such as the brake lever and brake pads (e.g., uneven pad wear and brake lever deformation), further reducing the lifespan and safety of the entire brake system, increasing maintenance costs and creating long-term safety risks.

Summary: While shaft wear may appear localized, it can actually lead to cascading safety risks such as brake failure and equipment loss of control. This is particularly true in industrial, medical, and logistics environments, potentially resulting in production interruptions, property damage, and personal injury. Regular inspections (for shake, shaft diameter, and cracks) and timely replacement of worn parts are essential to ensure safety.