AGV Caster Selection: Comprehensive Technical Guide from Material to Parameters

Efficient operation of AGVs and material carts in logistics scenarios relies heavily on precise caster selection. As critical components for load-bearing and mobility, caster materials, specifications, and compatibility directly affect equipment lifespan, operational efficiency, and floor protection. This article provides a detailed technical analysis from five dimensions: material characteristics, selection steps, core parameters, diameter-load comparison, and application scenarios.

1. Caster Material Performance: Optimal Material Selection for AGVs and Material Carts

Automotive logistics imposes five core requirements on casters: high wear resistance, low noise, floor protection, vibration resistance, and low rolling resistance. Different materials offer significant performance differences, and selecting the appropriate material is crucial.

1.1 Common Caster Material Performance Comparison

The table below compares the six key indicators for commonly used materials in automotive logistics: shock resistance, wear resistance, chemical resistance, floor protection, noise level, and operating temperature. Rating standard: S – Excellent, A – Good, B – Fair, C – Medium, D – Poor.

1.2 Optimal Material Conclusion

Considering the use of AGVs and material carts in logistics:

• Polyurethane (PU) is the optimal choice.

• Five core requirements (wear resistance, noise reduction, floor protection, shock absorption, low rolling resistance) all achieve “A” rating.

• Operating temperature (-20~80℃) covers typical indoor and outdoor automotive factory environments.

• Oil resistance and high load capacity match heavy-duty material cart requirements.

2. Caster Selection Steps: Four Steps to Ensure Precise Fit

The caster selection process should follow the sequence: load calculation → material selection → wheel core selection → wheel tread selection, ensuring each step meets technical requirements.

2.1 Step 1: Load Capacity Calculation (Core Formula and Safety Factor)

Load capacity is the foundation of caster selection. Calculate the required load per wheel and adjust safety factors according to operating conditions to avoid overloading.

Core formula (for four-wheel AGV/cart, excluding drive wheels):

$$Load\mathrm{\_}per\mathrm{\_}wheel=\frac{Weight\mathrm{\_}of\mathrm{\_}equipment+Max\mathrm{\_}load}{Number\mathrm{\_}of\mathrm{\_}wheels}\times Safety\mathrm{\_}Factor$$

• Load_per_wheel: Required load per wheel (kg)

• Weight_of_equipment: AGV or cart weight (kg)

• Max_load: Maximum payload (kg)

• Number_of_wheels: Number of support wheels

• Safety_Factor: Adjusted based on environment, mobility, and obstacle height

Safety factor classification:

2.2 Step 2: Caster Material Selection

• Priority: Polyurethane (PU)

• Hardness ≥ 92A to ensure low rolling resistance and high wear resistance, preventing deformation over long-term use.

2.3 Step 3: Wheel Core Selection

• Mandatory: Metal core recommended; plastic cores prohibited.

• Reason: Plastic cores expand under heat during high-frequency operation, causing separation from the tread and jamming AGV/cart.

2.4 Step 4: Wheel Tread Selection

• Principle: Select curved tread wheels where load capacity is sufficient.

• Advantage: Smaller contact area with floor reduces rolling friction by 15~20%, lowers AGV drive energy consumption, and improves operational efficiency.

3. Key Caster Parameters: Impacting AGV Performance

Performance parameters such as start-up efficiency, turning flexibility, and obstacle-crossing ability are determined by core specifications.

4. Wheel Diameter and Load Capacity Comparison Table

5. Application Scenarios and Selection Advice

• AGVs: Use PU wheels with curved tread, metal core, diameter 3~4 inches; ensure safety factor according to indoor/outdoor environment.

• Material Carts: Diameter ≥4 inches, PU92A, metal core, curved tread, load 500~800kg.

• Special Environments: For cleanrooms, consider non-marking wheels to prevent floor contamination.