Load capacity of casters and wheels

Our industrial casters quality control

The use of industrial castors in machinery and equipment is very important. The environment in production workshops is often particularly complex. This is why the requirements for the materials are also relatively high. The casters raw materials generally require a high level of impact resistance and strength. Polyurethane castors, for example, meet these requirements. They need to meet various standards and tests. Our caster wheels pass strict several quality tests.

① castor hardness test

Here mainly inspect the hardness of various caster materials. It needs to check the hardness of caster tyre treads and hardware such as bearings, brake pads, steel balls, etc.

We use a Shore A rubber hardness tester. Press it vertically onto the surface of the tyre. The hardness is the reading where the needle is stable for more than 3 seconds. For example, our 03 series PU polyurethane castor needs to meet hardness between 98 to 100 (Shore A).

Different types of industrial castors

Different braking devices, different industrial castors. We can classify castors into three main categories. That is, castors mainly include three types: fixed castors, universal casters and brake castors.

Fixed castors are not with a rotating structure. So they can only move in a straight line in a set direction. Universal castors, as the name implies, can rotate at will. The rotation direction is not restricted. This is why they are also known as movable castors. The brake caster is even more functional. It also involves a brake while ensuring that the caster can rotate in all directions.

In general, these three types of industrial casters are often used together. Like a normal trolley, universal casters work as the rear wheels. And fixed casters work as the front wheels. For mobile beds in hospitals, brake castors are used for the rear wheels. At the same time, fixed castors work as the two front wheels.

In addition, different mounting types, different castors and wheels. There are the following classifications: rigid castors, swivel casters, plate casters, stem mount castors, locking casters, etc.

(1) Rigid casters

The rigid castor is also called fixed caster. It has no rotating structure. Therefore it cannot rotate. Like the swivel castors, they help to save labour. But it can only go in a straight line. The advantage is that the castors are fixed in their orientation. This prevents the problem of disorientation that can be caused by four castors turning at the same time. Increase the speed of travel. However, when turning, the rigid industrial castors are not as casual as they could be.

They can walk fast. This kind of wheel is not prone to directional drift. Because the left and right directions are locked, you can only go forward or backward. Additionally, rigid casters are adaptable to uneven surfaces. So you can use them outdoors.

(2) Swivel casters

Swivel castors are also namely universal casters. It is the most common type of industrial caster and wheel. The rotating caster is also what we call a universal wheel. Its construction allows for a 360 degree rotation. So it can turn in any direction. It is particularly flexible and at your disposal. Avoiding the shortcomings of just walking in a straight line.

This rotating castor can turn sensitively in a flat plane. It is worth noting that the turning radius with the brake is different. But when walking fast, it tends to produce directional drift. This in turn leads to poor linear movement. The swivel castors are suitable for flat surfaces. They are generally used in more indoor conditions. Swivel casters of the same type tend to cost more than rigid castors. Because they are more complex to plan and have more functions.

Caster materials for choice

Industrial casters are available in a variety of materials. Accordingly, it includes PU polyurethane caster, PP polypropylene castors, PA nylon casters, ER natural rubber castors and TPR super artificial rubber casters. There also include metal castors, such as iron and stainless steel casters. Below is a table comparing the performance of various caster materials.

ed precise position positioning, you can choose a stepper motor or a servo motor.

What size casters do i need

Small belt conveyors are generally modular in design. So it’s very simple to install and disassemble. In addition, knowing the operation process is crucial to how to maintain the miniature convey

The conveyor belt is already connected well. Above all, set the support plate into the mini conveyor belt. Then, put the active roller and the driven roller in sequence. Afterwards, fix the 2 sets of guide rails on both sides.

How to select a right industrial castor

The industrial caster is a simple component. But choosing the wrong one can be tricky. The purpose of the caster is to facilitate handling. Choosing the right castor for your application and environment is vital.

(1) confirm the load-bearing weight

For castors of the same diameter, manufacturers generally produce several series. This allows them to be used for different load-bearing weights, such as light, medium, heavy duty, etc. The way is to make the wheels and brackets available in different thicknesses or materials.

In order to calculate the required load capacity of each caster, we must know the below weights. That is, know the weight of the transport equipment and objects. Of course, we also need to know the required castor quantity. The load capacity of a single wheel or caster is calculated as follows: T = (E + Z) / M x N;
T = the required load capacity of a industrial caster & wheel;
E = the weight of the transport equipment;
Z = weight of the moving object;
M = the effective number of loads carried by the wheel;
N = safety factor (approx. 1.3 – 1.5).

This calculation method increases insurance factor. Therefore, it’s more reliable. Prevents inadequate load-bearing, which can lead to a significant reduction in caster life or cause accidents. In general, we select the industrial castor according to the load-bearing capacity of 3 casters.

(2) what size casters do I need?

It also needs to confirm size when choosing castors. Generally speaking, the larger the caster diameter, the less thrust is required. At the same time, the friction on the ground increases as the contact area increases. The larger the diameter, the easier it will be to push or move your object. However, too large caster size will also result in too high a load or an off-center of gravity. Too large an eccentric distance will also reduces the load carrying capacity of the caster. Common industrial castor sizes are 2″, 2.5″, 3″, 3.5″, 4″, 5″, 6″, 8 inches, etc.

In addition, the width of industrial caster wheels will affect the load carrying capacity. Therefore the wider the caster, the more weight it can bear. If you are moving machinery or other heavy objects, you will need to consider using wider castors. If the load is lighter, for example on a work cart, you may want to choose a narrower caster. Many wheels are designed with a curved surface. The purpose is to reduce the contact area with the ground. They are usually available with “flat” or “rounded” edges.

(3) choose the right caster material

There are many options for caster materials. We should be fully aware of how the castors will be used and the application environment. Choosing the wrong wheel can lead to excessive wear and tear. So it will lead to more castors and more costs. Industrial castors should be flexible, lightweight and durable in use. On flat surfaces, hard materials are more flexible to turn. But on uneven ground, soft wheels are less strenuous.

Rubber castors:
Move softly and quiet;
Cannot be suitable oily environments;

PU polyurethane casters:
It can roll on most surfaces;
Performs well in oily environments;

PP polypropylene castors:
Price is relatively cheap;
Suitable for use on carpets and most surfaces;
Can be suitable for many chemicals;
Relatively low load-bearing capacity and noisy;

TPR casters:
Soft and flexible wheel surfaces;
The main advantages are eco-friendly and silence;
But the price is more expensive;

Castor bracket selection:

Industrial castors are available in both rigid and swivel. Usually we use the two types of casters together. The bracket material is generally carbon steel. Of course, apply various plating, such as galvanizing, copper plating, nickel plating, chrome plating etc. Stainless steel is also available.

The most common colors of caster brackets are silver and black. The silver color is achieved by plating with a layer of zinc or chrome. This gives the bracket a silvery color. The black ones are generally electrophoresis treated. This makes the bracket black.

(4) Cater bearing

There are several bearing types for industrial caster wheels. Namely, Terlin bearings, roller bearings, ball bearings, needle bearings and flat bearings.

Terlin bearings: It is special engineering plastic. It is suitable for all kinds of harsh environments, such as cold and heat, dry, wet and corrosive. And durable.

Roller bearings: industrial castors can carry heavier loads.

Ball bearings: suitable for higher loads, low noise levels and flexible rotation.

Needle roller bearings: particularly suitable for support structures where radial mounting dimensions are restricted.

Plain bearings: suitable for castors with high and very high loads and high speeds.

Double bearings are applicable in high-end castors. They are more stable, silent and have a higher load-bearing capacity than single bearings. Single bearings do not offer the same performance as double bearings. But the price is cheaper.

(5) Application environment of industrial castors

Many casters cannot be used in high temperature situations. Therefore, we need to be clear about the temperature range of each caster material. If use them at higher temperatures, they will usually lose their rigidity. This can lead to excessive wear on the industrial casters. In addition, it also consider the temperature range of the castor bearing. PU polyurethane casters can turn freely at -30°C. High-temperature resistant HPA casters can also move easily at temperatures up to 270°C.

On rough floors, should use the castors that are resistant to wear and have good elasticity. For example, we can choose the rubber, polyurethane or TPR industrial casters wheels. Elastic rubber wheels are very suitable for places such as hotels, offices. This is because it makes little noise when rolling. Nylon and iron castors are suitable for sites with uneven floors. Pneumatic wheels are suitable for light loads and where the surface is soft. In addition, some places require protection against static electricity. It is best to use special anti-static wheels. If in a clean room, ensure that the castors do not create marks on the floor.

(6) Installation of industrial casters & wheels

The installation connection of castors mainly includes two types. One type is the screw stem caster. The other type is the plate castor. The former has a threaded rod in the middle. For installation, need to process threaded holes at the end face of the aluminium profile. Then fix screw stem caster onto the end face. If there is no central hole, we can finish this with the aid of a connecting plate. It is also necessary to determine the mounting hole spacing and diameter of the caster base plate.

① Install 3pcs swivel casters

This mounting combination is suitable for handling drums and small equipment. It has good operability. Superior to four-wheel mounting methods of the same size.

② Install 4pcs swivel castors

This type of installation offers flexible rotation. It is possible to change direction freely even in tight spaces.

③ 2ps swivel casters and 2pcs rigid castors

If the rear two wheels are swivel, they can rotate easily. This is suitable for long distances and for roads with slope.

④ Install 4pcs rigid industrial castors

This is suitable for long straight transport of heavy equipment. Not for use on sloping working surfaces.

Applications of industrial caster and wheels

Industrial castors play an important role in the manufacturing industry. The manufacturing industry often requires the movement and handling of large machines, raw materials and components. Industrial castors are widely used in this industry. This is because they are able to move heavy items easily while protecting machines from damage.

The logistics and warehousing industry is also an important application field for industrial casters. This industry requires a great deal of moving and handling work. For examples, operate the loading and unloading of goods, the movement and handling of shelves, etc. We usually install the castors on shelving, trolleys, handling equipment and transport vehicles.

The healthcare industry is also an important application for industrial castors. For example, install casters on surgical beds, medical equipment and mobile cabinets. We need move and handle these devices frequently. At the same time, need to ensure their safety and stability. This is why the use of industrial casters is so important.

The retail industry is also application field for castors. For example, install them on shelves, display cabinets and shopping trolleys. They help to move and display goods easily. And at the same time increase efficiency. In addition, casters are also widely used in the furniture industry.

Caster wheel manufacturing process

Firstly, the designer will create the caster drawing as requirements. Secondly, the caster manufacturer will select the appropriate material, such as polyurethane, rubber, nylon, etc.

Production of industrial casters wheels: moulding, injection molding, extrusion, stamping, clamping, painting, assembly, etc.

① Injection molding part: baking – blanking – injection molding – take wheel out – trimming – cooling – assemble bearings.

② Hardware part: opening blanks – pressing – drilling – forming – heat treatment and plating.

The following is the introduction of the industrial castors production process. Illustrate it with the swivel casters.

Firstly, stamp the steel plate to size to form a sheet. At the same time, punch round holes out of the sheet.

Secondly, put the stamped sheets on the punching die. Stamp it into a bowl-shaped disc. In addition, punch the holder and the brake sheet into shape.

Thirdly, put lubricating oil in one circle of the bowl disc. Afterwards, put in the steel balls of the caster. The number of balls must not be enough. Then assemble the bracket to the bowl disc.

Fourthly, the bracket is fitted with oil and balls. You can also put in ball bearing.

Fifthly, fit the retainer and washers. Using a hydraulic press the small bowl disc. And rivete it to the holder. The steel balls will also be sealed together.

Sixth, melt the rubber in the machine. The press it to form the rubber wheel through the mould. Afterwards, remove the burrs on the rubber wheel. Of course, industrial castors are also available in PP, PVC, PU and nylon.

Finally, fit the shaft ring in the central hole of the rubber wheel. Use a screw to connect the rubber to the bracket. Next, fit the screw cap. In the end, test the caster on the machine. So the industrial caster is ready.

FAQ

1. 1. How to identify the material of industrial castors?

However, the PVC small conveyor belt has a strong odor when burning, and becomes hard material after burning.