Precision in Every Motion: Selecting and Installing Industrial Casters

Casters are indispensable elements in manufacturing, providing the necessary mobility to move heavy equipment, fixtures, and material carts across the factory floor. However, designing with casters goes far beyond simply bolting on a wheel; it requires technical precision in selection and installation to ensure safety, operational stability, and component longevity.

This article details the vast array of industrial caster types and provides essential engineering precautions for their reliable integration.

The appropriate caster type is dictated by the required motion, load distribution, and stability of the machine or cart. Selecting the right base and mounting method is the first step toward Precision in Every Motion.

Plate Type Swivel (Universal Type): Offers 360 degree rotation for maximum maneuverability. Requires precise vertical mounting to function correctly.

Plate Type Fixed: Allows movement in only a straight line. Used in tandem with swivel casters to provide directional control and stability.

Screw-In Type: Features a threaded stem for direct integration into machine frames or tubing, requiring careful torque application during installation.

Plug-In Type: Designed for quick insertion into specific sockets or hollow legs, often used for lighter-duty applications.

Through Hole Type / Angle Type: Variations in mounting plates designed for specific frame structures or corners.

Casters with Shock Absorber: Essential for equipment carrying sensitive loads or traversing uneven floors. The shock absorber minimizes vibration transfer, protecting the payload.

Casters with Leveling Mounts: Combines mobility with stabilization. Once the unit is moved, the leveling mount can be engaged to lift the wheel and create a rigid, stable base, ensuring precision during operation.

Beyond standard casters, specialized products further refine mobility:

• Dual Wheels: Increase stability and load capacity while potentially reducing floor wear.
• Corner Caster: Designed for installation at the corner of a frame, often allowing for complex movement patterns.
• Plate Type Ball Caster: Provides omni-directional movement for transferring materials or guiding parts on flat surfaces.

Failure to adhere to technical specifications during installation and operation can lead to component failure, reduced performance, and safety hazards.

1. Load and Speed Constraints

The published allowable load is a crucial constraint:

• Load Limit: The allowable load specified in product catalogs is based on manual transportation on a flat, even surface. Exceeding this load capacity will compromise the structural integrity and safety factor of the caster.
• Operating Speed: Casters are designed for intermittent use at low speeds. Avoid continuous use through power traction or in a hot state.
  • Wheel diameter 75 mm: Operating Speed 2 km/h
  • Wheel diameter100 mm: Operating Speed 4 km/h

2. Stopper Function and Safety

Caster stoppers (brakes) are subject to wear:

• Wear and Damage: Long-term use naturally reduces the efficiency of the stopper function. Engineers must be aware of this degradation.
• Supplementary Safety: Since braking force varies by material, additional safety measures (such as external wheel stoppers or dedicated braking parts) should be implemented when necessary to ensure product safety, especially for high-risk applications.

3. Operating Environment Limits

Casters are manufactured for standard conditions:

• Temperature Range: Casters are typically rated for use within the room temperature range –10 to 60C for the Economy Series).
• Chemical Exposure: Do not use standard casters in environments affected by high/low temperatures, high humidity, acids, alkalis, salts, solvents, oil, or sea water. These specialized environments require casters made from resistant materials (e.g., stainless steel or specific resins).

4. Precision Installation Methods

Proper installation is critical for maximizing caster life and operational stability:

• Mounting Surface: Ensure the mounting surface is as balanced (level) as possible to distribute the load evenly across all points.
• Swivel Casters: The rotary axis of the swivel caster must be in a vertical position to ensure smooth, unhindered rotation.
• Fixed Casters: Fixed casters must be mounted parallel to each other to prevent scrubbing and steering issues.
• Bolted Connections: Use appropriate bolts and nuts to secure plate-type casters reliably, preventing any looseness that could lead to vibration or damage.
• Screw-In Casters:Use caution when tightening the hexagonal part of the threads. Overtightening can cause stress concentration and result in shaft fracture. (Referencing a thread diameter of 12 mm, the appropriate tightening torque is typically 20 to 50 N m.)

4. Precision Installation Methods

Proper installation is critical for maximizing caster life and operational stability:

• Mounting Surface: Ensure the mounting surface is as balanced (level) as possible to distribute the load evenly across all points.
• Swivel Casters: The rotary axis of the swivel caster must be in a vertical position to ensure smooth, unhindered rotation.
• Fixed Casters: Fixed casters must be mounted parallel to each other to prevent scrubbing and steering issues.
• Bolted Connections: Use appropriate bolts and nuts to secure plate-type casters reliably, preventing any looseness that could lead to vibration or damage.
• Screw-In Casters:Use caution when tightening the hexagonal part of the threads. Overtightening can cause stress concentration and result in shaft fracture. (Referencing a thread diameter of 12 mm, the appropriate tightening torque is typically 20 to 50 N m.)

Casters are complex mechanical components that demand technical consideration to ensure Precision in Every Motion. By understanding load dynamics, speed limits, and strict installation procedures, you can integrate casters that provide reliable, safe, and long-lasting mobility.

Explore MiSUMi’s diverse range of casters, including the cost-effective and dependable Economy Series Rubber Casters, and utilize our detailed 3D CAD support and technical specifications to configure your perfect mobility solution.