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ICWM - Institute of Caster & Wheel Manufacturers

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When mounted to the underside of a piece of equipment, casters and wheels make it easier for personnel or machinery to transport a load or group of items from one place to another in a manufacturing or distribution facility. Typical industrial applications include platform trucks, carts, hand trucks, assemblies and tow line conveyor carriers.

What are Casters and Wheels?

There are several types of casters and wheels. These include:

  • Rigid (or stationary) casters – These fixed-position casters feature a wheel mounted to a stationary fork (also called a horn). The wheel can only roll along a straight line path. Accessories, such as wheel locks, prevent the caster wheel from moving to hold the load in place.
  • Swivel casters – Featuring a wheel mounted to a fork (also called a horn) that is mounted to a pivoting swivel joint, these casters can rotate a full 360° so the wheel can roll in any direction. Accessories, including caster locks, prevent the caster from swiveling to move the load in a single direction.
  • Wheels – Offered in a wide variety of hardness, materials, sizes, and treads. Wheel materials include:
  • Metal
  • Phenolic resin
  • Plastic
  • Pneumatic
  • Polyurethane
  • Rubber

The appropriate choice of caster wheels depends on many application-specific factors, such as:

  • Amount of use
  • Environmental conditions (moisture, extreme temperature)
  • Exposure to chemicals or liquids
  • Floor surface and condition
  • Load weight
  • Loading shocks
  • Noise restrictions
  • Speeds

Bearings and Accessories

Here are examples of 3 types of bearings used in the manufacturing on quality casters and wheels:

Manufacturers provide many accessories for specific applications:

  • Thread Guards prevent thread and material from clogging between the hub of the wheel and the inside of the fork. They remain stationary while the wheel revolves.
  • Grease Seals provide protection for swivel ball races and wheel bearings by keeping lubricant in and dirt out.
  • Swivel Locks are devices to prevent the rotation of the housing rig.
  • Wheel Brakes lock a caster and wheel by exerting hand or pressure on an operating level, forcing a brake shoe or band against the wheel hub or tread surface.
  • Swivel Lock/Wheel Brake eliminates the necessity of separate units for locking the swivel and the wheel.
  • Floor Lock attaches to the undercarriage of a truck to lock it in position.
  • Miscellaneous Accessories steering arms, rybar tubes, rubber bumper guards, shimmy dampeners and other items are available for specific applications. Consult your manufacturer.

Maintenance Tips

The user is responsible for proper maintenance and operation of equipment. Some equipment is abused or subjected to unreasonable demands. Don't overload or drop loads on carts or trucks. High speeds on rough floors can create severe impact or shock loads that may cause wheel or equipment failure. Periodically examine equipment for:

  • Frame and Fasteners: Tighten loose bolts and nuts and look for broken welds or deck boards. Look for frame distortion due to overloads or impact loads. A distorted frame can cause premature wheel failure because of abnormal loads on one or two casters. If casters are stem type, bolted or riveted in place, make sure the legs of the equipment are not bent and mounting bolts are properly secured. Always use lock nuts or lock washers in mounting casters. Be sure casters with expanding adapters in tubular equipment are held firmly in place.
  • Lubrication: Wheel and swivel bearings last longer if lubricated regularly. Some lube applied to friction points on the wheel hub, washer and leg surfaces of straight roller bearing systems reduces drag and improves reliability. Normal conditions may warrant lubrication every six months, but once a month may be necessary in a corrosive application. Cart washings may necessitate lubrication after each wash.
  • Wheels: Check for visible points of tread wear. Flat spots may indicate foreign material, such as string, thread, etc., causing wheels to bind. Thread guards will delay build-up of such materials. Loose casters or frozen wheels are other causes of this problem. Replace wheel and/or caster to avoid erratic rolling. After inspecting and making corrections, be sure axle nut is properly tightened. Use lock washers or nuts on all axles. Tighten loose axle immediately to avoid becoming cocked in the caster housing/rig and locking up. Keep replacement wheels and bearings on hand to avoid costly downtime.
  • Casters: If swivel assembly is loose, it may need to be replaced. If caster has a king bolt nut, make sure it is securely fastened. If swivel assembly does not turn freely, check raceways for corrosion or dirt. If equipment has rigid casters at one end, make sure caster housing/rig is not bent.

How are Casters and Wheels Used?

Casters and wheels are used in a variety of areas to support processing and picking throughout a facility:

  • Assembly: Transporting loads to, from and through assembly processes
  • Order picking: On carts and forklifts, transporting pallets and totes throughout a facility
  • Production: Moving in-process parts through a production line
  • Replenishment: Transferring items from storage to picking locations
  • Transport: Moving loads and equipment throughout a facility

What are the Benefits?

Casters and wheels provide a variety of benefits:

  • Mobility – Adding wheels and casters to a platform or piece of equipment makes it easy to transport a load or machinery throughout a facility to support processing and handling
  • Ergonomics – Because they facilitate motion, wheels and casters lessen physical strains and stresses on personnel as they move heavy loads
  • Transport – Wheels and casters enable easier storage and manufacturing processes because they help to speed the travel of component parts and inventory throughout a facility

Where are Wheels Used?

Casters and wheels are used in nearly every industry, including:

  • Automotive
  • Bakery
  • Beverage
  • Chemical
  • Electronics
  • Food
  • Hospital
  • Manufacturing
  • Office
  • Paper
  • Plastics
  • Retail
  • Warehousing and distribution
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