Six Advantages of Utilizing Air Casters in Industrial Operations

The assembly processes within manufacturing companies can be intricate, especially when dealing with larger and heavier products. Effective and safe movement of such substantial objects is crucial to prevent downtime, which can result in significant costs. In this article, we explore the advantages of air casters as a valuable tool for transporting heavy loads, such as machines, skids, and large structures, aiming to optimize production processes and minimize downtime.

  1. Enhanced Maneuverability in Confined Spaces: Air casters facilitate the movement of heavy loads by allowing them to float on a thin layer of air, enabling almost frictionless motion in any direction. This freedom of movement is particularly beneficial for navigating larger objects through smaller spaces, sharp turns, or narrow passages. With only 1 pound of force needed to move 1,000 pounds, air casters provide unparalleled maneuverability, comparable to the workings of a hovercraft but without the massive propellers.

  2. Safety and Ergonomic Advantages: In production environments where numerous employees are involved in moving heavy loads, safety and ergonomics are paramount. Air casters enable the movement of several thousand kilograms by a single person, or with the assistance of multiple individuals for heavier loads. ASE System Company’s engineering team offers customized solutions to ensure safe and ergonomic internal logistics.

  3. Reduced Risk of Floor Damage: The air cushion between the air casters and the floor minimizes friction, preventing contact and reducing the risk of damage to the floor. Additionally, the weight of the load is evenly distributed over the entire surface of the air caster, resulting in lower floor pressure and eliminating line or point loads. With a maximum working pressure of 4 bar, the pressure on the floor never exceeds 4 kg per cm2.

  4. Minimal Maintenance Requirements: Air casters boast a maintenance-friendly design with no moving parts, eliminating the need for lubrication or oil. Cleaning them is a simple task with soap and water if they accumulate dirt.

  5. Vibration-Free Transport of Fragile Loads: Air casters excel in transporting loads sensitive to shocks and vibrations. Unevenness in the floor is absorbed by the air caster, preventing vibrations from reaching the load. This makes air casters ideal for moving high-tech equipment or other delicate items, acting as a buffer or shock absorber between the load and the floor.

  6. Effortless Handling of Heavy Loads: Regardless of the weight or size of heavy machinery or loads, air casters provide a solution. With the ability to give the entire load a floating position on a well-prepared floor, air casters reduce friction, requiring only a fraction of the force to set a weight in motion. Safety remains a top priority, ensuring that despite the ease of movement, the weight remains unchanged.

In summary, the benefits of air casters include optimal maneuverability, safe and ergonomic moving of heavy loads, reduced floor pressure, minimal maintenance requirements, and vibration-free transport of sensitive loads or machinery. ASE System Company continues to revolutionize the industrial landscape by offering innovative solutions that enhance efficiency and safety in the movement of heavy loads within manufacturing environments.

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Air Casters and Industrial Floor Protection Methods

Industrial floor surfaces often prove more delicate than commonly perceived, making them susceptible to damage and displaying signs of wear and tear easily if not adequately protected. Preserving floor conditions can be challenging, given the various factors that can lead to extensive and costly damage, impacting both operations and safety.

Exploring effective industrial floor protection methods becomes crucial to ensure the longevity of these surfaces and instill confidence in their ability to withstand the test of time.

Air Casters and Surface Preservation:

Not all machinery and equipment used for load movement pose a threat to industrial floors. Air casters stand out as a notable exception. Unlike conventional wheeled counterparts found in most industrial settings, air casters don’t roll over the floor’s surface; instead, they float above it. Utilizing compressed air, these donut-shaped elements create a thin film of air between the load and the ground, allowing the load to hover above the floor surface.

Efficient use of air casters hinges on the quality of the industrial floor surface. Issues like porous surfaces, cracks, or gaps can impede the maintenance of the wafer-thin, frictionless air film that keeps the load afloat. In such cases, remediation or repairs may be necessary. Modern solutions like epoxy treatment are popular, and simpler adjustments, such as a plastic or thin sheet metal overlay, can also suffice. Once these modifications are implemented, air casters effortlessly glide over floors, even those with rough or uneven surfaces, without causing further damage. Additionally, the grinding noise associated with heavy equipment on floor surfaces is significantly reduced or eliminated.

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How Technology Makes Heavy Equipment Movement Easier

As technology continues to advance, the challenges associated with the movement of heavy equipment are gradually diminishing. Innovative tools have emerged to simplify this task for your team, offering efficiency and ease in handling substantial loads.

Roller Skids:

Ideal for confined spaces and delicate environments, roller skids prove to be a convenient solution. These compact transportation tools provide an easy-to-use platform for placing heavy equipment, allowing effortless rolling without the need to drag the load and risk damaging the floors. Larger machines may require additional support to bear the weight effectively.

Toe Jacks:
While toe jacks are not designed for moving machinery or materials on their own, they serve as a valuable complement to other moving equipment. When using roller skids, for instance, toe jacks come into play for lifting the equipment and positioning the skids. This ensures that your team can lift heavy objects without posing any risks to their bodies.
Air Bearings:

For particularly heavy equipment, the challenge of movement becomes more pronounced. Air bearings offer a solution by utilizing a platform that uses pressurized air to keep the equipment off the ground. This technology makes tons of equipment more maneuverable, eliminating concerns about floor damage as the load glides on a thin layer of pressurized air.

Lift Buddy:
When tackling lifting tasks solo and seeking assistance, the lift buddy proves to be a valuable piece of equipment. Tailored for smaller tasks, it isn’t designed for extremely heavy machinery but provides crucial support for tasks that would typically require more than one person, fostering a more efficient work environment.
Lifting Straps:

Manual lifting of heavy materials without specialized equipment can pose significant challenges, especially in terms of pressure on the individual lifting. Lifting straps come to the rescue by helping distribute the weight into a better position, reducing the risk of back injuries. This simple tool, wrapped around shoulders or forearms, makes manual lifting more manageable and safer.

Rotating Dollies:
In compact spaces where traditional heavy-duty movement equipment may struggle to navigate, rotating dollies emerge as a practical solution. These small platforms with rotating wheels can support substantial loads, providing a means to safely transport heavy equipment even in confined environments, ensuring efficient movement without compromising safety.

Case Studies

Click Below to Download Handling Automotive Assembly

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