Caster Engineering

Aerol was built to provide solutions to the most challenging mobility issues in material handling. Our manufacturing and caster engineering process is highly flexible and allows us to accommodate custom designs with high precision easily. Our tools are designed to make caster and caster wheel adjustments quick and easy. Over the years, we have worked closely with numerous engineers to develop the following tools and resources specifically to help our engineers meet your specific needs:

CAD Model Tool

  • Our CAD Model Tool enables customization of the thousands of existing models
  • Download models in one of over 50 formats, ensuring compatibility with your design application

We offer extensive knowledge and experience in resolving common challenges, including:

  • Ergonomics
  • Extreme Weight (Up to Several Hundred Tons)
  • Environmental Challenges
  • Powered Applications
  • Noise Reduction
  • Harsh and Abusive Conditions
  • ROI Improvements Around Material Handling

Caster and Caster Wheel Dyno Testing

Dyno Testing
Our fully automated caster testing machines simulate the real-world use of their products in a laboratory setting. The Dynamic Wheel Endurance Test Machine (DWETM) is computer-controlled and can run unattended continuously.

The list of features of the DWETM includes:

  • Automatic changing of testing conditions, load, speed, and test duration
  • Ability to simulate static and dynamic loads up to 10,000 pounds and speeds up to 20 mph
  • Ability to automatically stop testing sessions when it senses a failure condition
  • A force load cell to measure load on the test product
  • A torque and speed sensor to measure the speed of the wheel and the torque being exerted onto the test wheel
  • An infrared temperature sensor to measure wheel temperature
  • An accelerometer to measure machine vibration
  • All testing data from the DWETM is fed directly into a computer-based controller and can be reviewed and analyzed using software designed specifically for this purpose

Portable, Continuous Ergonomic Pull Tester (PCEPT)

Caster Concepts engineers have also developed the Portable Continuous Ergonomic Pull Tester (PCEPT). It is a tool to acquire and record pull-force data with high accuracy and repetition. This semi-automated portable testing machine can simultaneously measure, display, and record pulls force data and pull speed data.

The PCEPT’s computer-based data acquisition system records all incoming data, and the custom-designed software allows the data to be retrieved and analyzed. An open-loop motor controller ensures that run conditions remain constant between different test sessions, resulting in repeatable and consistent measurements.

Multi-functional Static Condition Caster Test Machine (SCCTM)

The multifunctional Static Condition Caster Test Machine was built to verify and quantify the static characteristics of Caster Concepts’ current and future product lines. Specifically, the static tester can continuously measure the stiffness profile of spring-loaded and other shock absorption casters along their entire travel length. It can also be used to determine tread bond strength and quality of elastomer-treaded wheels. Additionally, the static tester can continuously measure the resulting footprint of a wheel concerning the load applied, thus capturing the change in footprint area as the load applied to the wheel is varied.

We aimed to create a low-cost, multi-functional machine capable of generating useful data for various products. Much of the SCCTM functionality is not automated to reduce costs and maintain flexibility. Since each specimen’s operation and testing time is relatively short, an operator must always be present. The operator’s duties in running the test machine include loading and unloading specimens, initiating the data acquisition software, and controlling the force actuation mechanism.

The SCCTM’s hydraulic cylinder and S beam load cell can generate and measure 20,000 pounds of force. The cylinder has 10 inches of travel measured through a linear encoder. With the addition of extension rods, its plunging height can be further adjusted to accommodate various caster sizes.

Proven Solutions

From custom drive platforms to driving simulators to a dyno testing station, we’ve applied our caster engineering expertise across various applications. Caster Concepts is capable of handling everything. From product development, finite element analysis, CAD, and manufacturing documentation to creating prototypes, proof of concepts, and large production runs. Our vertically integrated manufacturing process reduces design time and expenses.

Over the past decade, the engineering department at Caster Concepts has developed into one of the most highly sought-after services in the industry. With access to tools including the SolidWorks CAD design platform, Finite Element Analysis (FEA) and design, prototype dynamic testing, laser cutting, CNC forming, varying durometers of polyurethane wheels, varying chemical makeup of polyurethane wheels, robotic welding, and ISO-supported manufacturing processes, Caster Concepts offers a wide range of services.