air caster

8/12/2019 Air Caster

1/25

SUBMITTED TO:Prof. B.B. SATPATHY

Er. SANTOSH PANDA

Dept. of MECHANICAL ENGINEERING

SUBMITTED BY:JITENJAYA PATTNAIK

REGD NO: 1001217095

7THSEM, MECH. ENGG

PKACE BARGARH


2/25

CERTIFIC TE

This is to certify that Mr. JITENJAYAPATTNAIK, a student of 7thsemester,

mechanical engineering of PadmashreeKrutartha Acharya College Of Engineeringbearing Regd. No. 1001217195 has takenactive interest in preparing his seminar reportin

AIR CASTER

This is in partial fulfilment of requirement

for the Bachelor of Technology degree in

Mechanical Engineering, under Biju Pattnaik

University of Technology, Orissa. We wish

him all the best for his bright future &endeavour.

Asst. Prof. B.B.SATPATHY SANTOSH PANDA

HOD (MECH) LECTURER(MECH)


3/25

CKNOWLEDGEMENT

THE SATISFACTION THAT ACCOMPANIES THE

SUCCESSFUL COMPLETION OF THE TASK WOULD BE

INCOMPLETE WITHOUT THE MENTION OF THE

PEOPLE WHO MADE IT POSSIBLE & WHOSE

CONSTANT GUIDENCE CROWNS ALL EFFORTS WITH

SUCCESS.

I EXPRESS MY DEEP SENSE OF GRATITUDE TO Prof.

B.B.SATHPATHY, Er. SANTOSH PANDA, DEPARTMENT

OF MECHANICAL ENGINEERING FOR THEIR INITIATIVE

AND CONSTANT INSPIRATION.

LASTLY I EXPRESS MY GRATITUDE TO ALL

THE LECTURERS, LAB INSTRUCTOR AND FRIENDS

FOR THEIR COOPERATIVE HAND THEIR VALUABLE

SUGGESTION DURING THE PREPARATION OF THIS

SEMINAR REPORT.

THANK YOU


4/25

INTRODUCTION

Casters are small wheels designed to make furniture,

appliances& machinery move from one place to another easily. Inair caster air is used to move machinery in place of wheels. An air

caster is a pneumatic lifting device use to move heavy loads flat,

non-porous surfaces. It uses a thin layer of air as a way to float a

very small distance off the ground.

Air casters go by names including air pads, air skates, air skids

& air bearings. No matter which term is used they all share the

common premise of floating heavy loads on film of air.

HISTORY

The air caster was invented in the late 1950 by britishhovercraft corporation. Who after inventing hovercraft went on to

produce the BHC HOVERPAD. The leading companies who

produce air casters are Air float,Air caster corporation,Aero

go,Aeris,Aovair, Vertex,Airofilm.

AIR BEARING CASTERS COMPONENTS

1). MAIN AIR HOSE:Length is 30.0 meters. One of the

ends connected with the air power source. Another end

connects the control console. If one piece main air hose

cant meet your requirement, more hoses are workable.


5/25

Butdo not more than 5 pieces. Means no more than 150.0

meters is workable. The main air hose need air power flow

is no less than 13 stere per minute. Main air pressure needs

no less than 7.0 KG per CM2.

2). AIR CONTROL CONSOLE: Controlled the air flow, have

dial gauges, when adjusting the air flow, please follow this

dial gauges performance slowly to increase the value.

3). Have 6 pieces vice air hoses, one pieces length is

6.0 meters.

4). Have 6 piecesair skates, one pieces air skates

capacity is 8.0 T. Dimension is 686mm686mm50mm.

Every air skates air power need 0.40 MPA. The air skates

material is alloy steel 6061.

WHAT IS AN AIR BEARING OR AIR CASTER?

Air Bearings are also known as Air Casters, they are one in the

same. An air caster / air bearing is made of reinforced rubber.

The circular rubber torus is vulcanized to an anodized alluminum

back plate. When the air bearing is deflated, the load rests on the

landing pad in the center of the module . On larger capacity

models the air caster also includes landing pads in the thecorners

for added support. The aluminium back plate is bolted to a rigid

load platform. The load module top plate is an alluminum

extrusion, with a very high strength to weight ratio. The supply o

compressed air enters through a port in the end of the module,

then through the torus forcing a thin air film on which the load

floats with a minimum of friction. A seal is formed between the

floor surface and the torus.


6/25

AeroGo air caster

equipment uses a variety of air

casters to literally float heavy

loads on a virtually frictionlessfilm of air which provides a

provides a clean, quiet and safe

alternative for heavy load

handling systems.

Reduced friction and

omni-directional transfer allow precise handling of the load,

giving the operator a better ability to maneuver and align the air

bearing in a limited work space. The low profile of the air caster

Load Module requires less than 3-inch (76mm) clearance. An air

caster will not damage floors and expensive reinforcement is

usually not necessary.

Because we use only basic pneumatic components such as

air regulators and hoses, our load modules and air bearingsystems are not only reliable, but will operate in most

environments unlike some other types of heavy load handling

systems.

The Air Caster is a unique product that offers many

benefits for Heavy Load Moving including a rapid return on

investment (ROI), increased productivity, flexibility in leanmanufacturing setups, reduced worker compensation claims, and

improved operator environment to industrial corporations of any

size or type especially in light of todays competitive environment.

The Air Caster is ideal for Machinery Moving such as stamping

presses, injection mold machines, CNC machine tools, welded

fabrications, vibration sensitive electronic equipment and evenlarge seating sections found in theatres or convention centers.

This is just a small sample of typical applications.


7/25

Air casters are either round steel or square aluminum

extrusions that are fitted with valves and air bearings to form

what is known as an air caster. They are typically used to sit

underneath heavy loads and machines and move them to where

they need to go. They are similar to normal casters, wheels ordollies, but they are far superior, can lift and move weights in

excess of 50 tons and WILL NOT DAMAGE YOUR FLOORS.

CONNECTING COMPRESSED AIR TO AN AIR

CASTERS LOAD MOVING SYSTEM?

After the initial assembly and footprint connection is done,

you can now move on to connecting the source of your

compressed air- usually your compressor - to the air caster load

moving system.

With the footprint all hooked up, hose lines locked into

place, it is now time to connect the air caster systemto your source

of compressed air - normally your compressor. Most factories,

warehouses, workshops etc. have a supply of compressed air

running around the roof area of the premises. Usually formed into

a ring of pipework, there are compressed air drops at regular

intervals.

Locate a compressed air dropin your company's system

and connect into the system there for your supply of compressed

air to the load moving equipment. If you don't have a compressed

air drop, you will need to pull your air from one of the connections

at the compressor.


8/25

Connecting compressed air to

a Hovair Systemis relatively

easy providing you follow some

common sense directions. All

Hovair operator manuals

include several pages of general

safety and compressed air

safety. The main rule for

connecting up a system to the air source is to make sure that

everything is first turned OFF. Compressed air can be dangerous if

it not under control at all times.

Air caster systems can handle their loads with long

lengths of air hose line from the drop position or compressor. As

long as you have a constant supply of compressed air from the

compressor to the system - around 90 psi - and the correct hose

size feeding the system, you can have quite a long hose line

supplying your system.

HOW ARE AIR CASTERS POWERED?Air casters are powered pneumaticallywith compressed

air. Generally the compressed airneeds to be clean and filtered.

Most modern shop compressors have filters attached that ensure

the outgoing air is clean and free of particulate.Most companies

have compressors installed in their works, and if so, apart from

the generating of the air, the air caster load moving equipment

will run at virtually no cost.

There is no electricity*required,

nor do you need propane or

other gasses, diesel or oil of any

sort. Just plug in a compressed

air line and off you go. It really

is that easy!
http://www.aircasters.com/images/b-bearing-footprint-diagram.gifhttp://www.aircasters.com/images/b-bearing-footprint-diagram.gif


9/25

HOW DOES EVERYTHING CONNECT UP?

Connecting up your air casters to form a load moving

system is relatively easy. Each air caster is laid on the floor in a

rough format that matches the shape of the load. The fitted valvesshould face the outside of the footprint's shape.

Here is a typicalair caster systemfootprint after assembly, an

line hose with quick-disconnect fittings, and a selection

connections and fittings you are likely to

find in an air bearing system.

Each air caster modulewill have apre-fitted air flow control valve in the

load module assembly. The supplied air

line hoses each fit to one of these valves

and snaps into position using the quick

connect fittings at the end of each hose.

After each hoseis connected to the

corresponding air caster loadmodule, the unused end should

be lying to the outside of the

footprint.

Here is a diagram of a

typical air caster - air hose fit

using a quick connect fitting.These fittings are standard onall Hovair Systems air caster

kit systems.


10/25

With all air hoses

connected to the load

modules, the air line hoses

should be connected to the

remaining hardware whichwill eventually end at the air

inlet port at the end of the

system - supplied ball valve

usually.

That should take care of the assembly and hook-up of the air

castersin your system.Remember, we have an excellent sales and support teamto

help you with your load moving needs. We can easily explain most

things to you, and also advise you of any options that may be

available to you. We give you choices and options - never any

pressure.

WORKING PRINCIPLE

Modules are fitted to a special load platform or

individually positioned directly under the load. In order to achieve

stability, at least three, but most often four, modules are placed

under the load. (The three-legged stool principle.) These are

connected through a pneumatic control unit, to a compressed air

supply. Modules should be positioned as far apart as possible inorder to optimize the weight distribution and load stability. Once

the modules have been positioned, the valves can be opened

individually. The pressure in the air bearings can be increased

slowly until they lift the load and it starts to float. The load can

then be moved and be positioned exactly as required.


11/25

OPERATION OF AIR BEARING

CASTERS

WHEN ENERGIZED WITH A COMPRESSED AIR

SUPPLY, THE FOLLOWING SEQUENCE OF EVENTSTAKES PLACE

1.) The circular reinforced rubbe

bellows inflates and fills the gap

between the mounting plate and the

floor.

2.) As the pressure increases, the

mounting plate and its landing pads,

lifts off the floor.

3.) When the pressure in the

bellows is higher than the counter

pressure of the load, the air flows out

from the bellows forming a thin air

film on which the load floats

practically friction-free.

A flexible, wear-resistant urethane diaphragm is inflated by

compressed air, forming a seal with the floor and lifting the

structure off its rest pads. Air is then squeezed between the floor

and the diaphragm, creating a thin film of air and allowing the

load to float.

On a smooth floor, this air film allows for nearly friction free

movement in any direction. With an excellent air bearing floor, the

volume of air required can be very low, which results in a very

efficient operation. When floating on air bearings, a 1000-lb. load

can be moved with about 1 pound of force thats 10 times better

than conventional wheels or casters


12/25

Air bearings are constructed of a smooth-textured,

completely homogeneous material. When pressured the bearing

will stretch uniformly and closely follow the contours of the floor,

maintaining a consistent air film. This is evident with lower drag

forces and less air consumption than that produced by fabric-

reinforced air bearings used by some competitors.

PRODUCTS

AIR CASTER AIR BEARINGS

Air bearings eliminate

friction to allow movementof heavy loads

Air Caster Corporation

offers a full range of air

bearings for moving loads from

a few hundred pounds to over

100,000 pounds. All airbearings are made with a tough

wear resistant urethane diaphragm, giving superior performance


13/25

compared to other air film devices. The diaphragm is securely

attached to a corrosion resistant steel backing. For convenience, all

air bearing have a female pipe thread air inlet for direct

connection, and a seal ring for slide out mounting.

OFFERING

AIR CASTERNO.

SIZE(IN.)

CAPACITY(LBS.)

AIRINLET(FPT)

AIRFLOW(CFM)

LIFT(IN.)

AC-10 10 x 10 1000 8

AC-14 14 x 14 2000 3/8 12 5/8

AC-18 18 x 18 5000 3/8 16

AC-22 22 x 22 7500 20 1

AC-30 30 x 30 15,000 32 1 1/8

AC-34 34 x 34 20,000 36 1

AC-46 46 x 46 36,000 50 1

AIR PALLETS AND AIR BEARING

TRANSPORTERS

Air Caster platforms, our air pallets and air bearing

transporters (pallets with drive tractors), are solving heavy load

movement problems for many industries.


14/25

HOW AIR CASTER PLATFORMS WORK?

Likeair bearing movers,Our air pallets and transporters

are equipped with air bearings that support and move heavy

loads on a thin film of air. This air film eliminates friction,

allowing loads to be moved with only 1/10 the amount of forcethat would be required on wheels.

Air bearing transporter with support fixturing that is custom

designed to meet load size. The top deck of the Air Caster platform

can be configured to provide a complete load handling system.

Air Caster platforms are welded structural steel and

available in standard sizes as well as custom sizes and

configurations. Load capacities range from 4,000 pounds to well

over 100,000 pounds.

APPLICATIONS FOR AIR PALLETS AND AIR

BEARING TRANSPORTERSMould and die handling

Transfers between crane bays

Assembly line movement of product or

subassemblies

oHeavy construction

oHeavy electrical

oAutomotiveMoving loads into test cells, coordinate measuring

machine rooms
http://www.aircaster.com/air-caster-movershttp://www.aircaster.com/air-caster-movershttp://www.aircaster.com/air-caster-movershttp://www.aircaster.com/air-caster-movers


15/25

Moving machine tools, process equipment

Assembly fixtures

Heavy load Air Caster platform s (capaci ty to 140,000 pou nds )

General purpo se Air Caster platforms (capaci ty to 6,000 poun ds)

ADJUSTABLE HEIGHT WORK PLATFORMS

The need for adjustable height work platforms can occur

whereveroperator working height changes due to changes in

machine or tooling height. Model or product changes can result in

changes in working height. The need can also occur where the

working height is fixed, but the physical height of the operators

varies.

With Ergo stand Adjustable Height Work Platforms and the

larger Custom Adjustable Height Platforms, operators can now

adjust their working height for maximum efficiency. Other

benefits provided by by these ergonomic work platforms include:

Improved work station ergonomics by allowing

operators to work at their most comfortable height


16/25

Reduce fatigue and increase productivity

Lower-cost solution compared to cost of changing

line height or height of machine or process

Ergo stand and Custom Adjustable Height Platforms

are available in both standard and custom sizes which

include:

oHeavy steel construction for a firm, steady

support deck

oFully adjustable throughout lift range

oEasy height adjustment with foot valve

up/down control

oEasy installation. Simply connect to plant air

supply line

PNEUMATIC SCISSOR LIFTS AND MORE

Ergonomic part handling and positioning with pneumatic

scissor lifts, lift and rotates, and lift and tilts

Air Caster Corporation provides a variety of equipment to

position parts ergonomically for operator access. These includepneumatic scissor lifts, lift and rotates, and lift and tilts. All units

are pneumatically (plant air) powered and are easily operated by

hand or foot controls. Oversized top decks are also available.

Air Caster's scissor lifts, lift and rotates, and lift and tilts

offer these significant features:

Easy installation; simply connect plant air hose tounit

Permanently lubricated bearings


17/25

Hardened and polished pivot pins

Serviceable, high load capacity rollers

Foot valve or pedestal controls

Optional safety skirt

Air/hydraulic Air Caster's scissor lifts can be providedfor applications that require a lift with firm, solid support at any

height. Pneumatic scissor lifts, lift and rotates, and lift and tilts are

also available for low height applications.

APPLICATIONS

NUCLEAR

Weight 150 tons

LoadSpent fuel storage casket

Solution To maneuver this spent fuel storage cask into

temporary storage, AeroGo engineers designed a convenientsolution using the AeroGo transporter system.

ROLL HANDLING

Using just standard shop air, AeroGos Rollmover and

Rollmaster II make it possible for a single person to easily

floatheavy paper rolls, metal sheet coils, cable reels and othersimilar loads on a thin film of compressed air without the use of

bulky overhead cranes, forklifts, rails or floor track systems. This


18/25

unique air caster technology provides a reliable and easy-to-use

alternative for your roll movement needs.

POWER GENERATION

Weight 80,000 lbs.

LoadFeed water heater

SolutionWhen a customer needed to replace a feed water

heater in a power plant, the customer identified AeroGo's loadmodule system as the most efficient solution.

RIGGING

Air Caster Rigging Systems are a proven method to move

oversized, awkward, uneven or heavy loads. The 4 and 6 load

module systems (also known as air caster rigging systems) easily

adapt to any load configuration to effectively distribute heavy loadweight across the floor.


19/25

TRANSFORMER MANUFACTURINGWeight250 tons

ApplicationPower distribution transformers

Solution A customer needed to transport power

distribution transformers up to 800 tons through themanufacturing process and in and out of vapor phase ovens.

VEHICLE ASSEMBLY

Weight40,000 lbs.

Load Recreational vehicles

Solution A customer needed to move a recreational

vehicle through the assembly process. AeroGo engineers used


20/25

AeroGo Aero-Pallets to develop an easy, cost efficientsolution that

relied on standard shop air while guaranteeing precise movement

and positioning.

LOADRUNNER

Move 2,500 lbs. with the touch of a finger

Will not damage the load or the floor

Ideal for manufacturing, assembly and warehouse

Lightweight and manoeuvrable

Intuitive throttle-style fingertip controls

Aero-Caster technology floats the load

Built-in compressed air (no air hose)

Deck size 42" wide x 49" long

Aerospace

Weight

220 tonsLoadSolid rocket segment


21/25

Solution An aerospace customer needed to transport a solid

rocket segment.

AeroGo engineers customized a successful solution using AeroGo

air cushion transporters, which have been used to move loads

weighing over 2,000 tons.

ADVANTAGES

EFFICIENCYPrecise positioning to mandrels without

damage caused by traditional material handling equipmentmethods.

USER-FRIENDLYProvides clean and ergonomic roll

handling lifts, and can be customized with T-bar handle, no-

load wheels or Tie Bar pair for added stability.

SAFE TO USEWith no moving parts, the Rollmaster

increases employee safety

and reduces lift hazards. System reduces floor loading to an acceptable level

Operator could easily change direction and manoeuvre

through tight spaces

Aerospace-grade aluminium pallets are 50% lighter than

steel

Eliminated the need for fixed in-floor fixtures and secondary

equipment Reduced queue time and transfer time, which resulted in

production increase


22/25

Personnel quickly learned to use the system, saving time

and resources

Independent movement of units eliminated delays in

production cycle

Aero-Pallet maximized floor space utilization without

restricting assembly flow to a fixed path

Line flow and product positioning was changed with no

additional costs

Air casters / Air Bearings are generally used in lieu of

wheels and have many advantages. All thats needed is a source of

compressed air; a smooth sealed surface such as concrete, epoxycoated, or steel floor and a load ranging in weight from 200

pounds to 5000 tons. Some of the technical features that make air

casters the preferred choice for moving heavy, bulky or sensitive

loads are as follows:

Low friction force

Omni or 4 directional moti Precise positioning

Protects floor finish

Eliminates need for fork

trucks or overhead cranes

Operates on plant air

Clean and quiet operat Low surface loading

Gently move sensitive

loads

Safely move and contr

heavy loads

LIMITATION

Air caster requires a smooth, non porous surface in order to

maintain lift and operate properly. Cracks and other surface

defects can interrupt the proper flow of air.


23/25

CONCLUSION

Air is the most abundant substance on the world, it is available

everywhere and free of cost. So why dont we utilise it for useful

purposes. Air film technology is the most suitable option for

transporting heavy loads with minimum effort and cost by AIR

CASTER.


24/25


25/25

EXPERT REVIEWS

1.

2.

3.

THANK YOU

air caster

Documents