1. Mathematical Load Capacity Calculation Formula
When engineering material handling carts or AGV platforms, total load weight must never be divided equally across all four wheels. Uneven floor distribution and sudden shock loads require a safety distribution factor (usually calculating across 3 wheels instead of 4):
Caster Load Capacity (L) = (Equipment Weight + Max Payload Weight) 3 Safety Factor (1.2 to 1.5)
2. Wheel Tread Material Comparison Matrix
| Material Type | Shore Hardness | Load Rating Range | Floor Protection | Best Application |
|---|---|---|---|---|
| Polyurethane (PU on Cast Iron) | 90A - 95A | 500 kg - 2,500 kg | High (Non-marking) | Automotive Assembly, Heavy AGVs, Warehouse Concrete |
| Nylon (Polyamide) | 75D | 800 kg - 3,000 kg | Moderate | Food Processing, Chemical Exposure, High Moisture |
| Forged Steel / Ductile Iron | 160 BHN | 2,000 kg - 10,000 kg | Low (Metal Floor/Tracks) | Heavy Machinery Transport, Aircraft Hangar Equipment |
3. Environmental & Rolling Resistance Considerations
- Ergonomic Push/Pull Force: Larger diameter wheels (6" to 8") reduce manual startup inertia by up to 35% compared to 4" options.
- Bearing Type Selection: Precision sealed ball bearings offer lowest roll resistance; tapered roller bearings handle extreme side-thrust forces during towing.
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