air caster
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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
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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)
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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
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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.
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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.
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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.
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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.
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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!
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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.
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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.
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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
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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
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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.
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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
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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
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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
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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
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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.
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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
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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
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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
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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.
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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.
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EXPERT REVIEWS
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THANK YOU
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