CCoonnvveeyyoorr && SSppeecciiaall CCaasstteerrss

Conveyor & Special Casters

57 Series Customer: Automotive Manufacturer Application: Industrial Carts in a forklift free environment Issue: The Company was moving toward a forklift free environment and needed a product that was durable, easy to roll and quiet. Solution: After rigorous testing done by the company it was determined that the Caster Concepts caster required 25% less force to move loaded carts as well as reduced noise and was the best ergonomic choice. The company has standardized the use of this caster within their facility and continues to work closely with the team at Caster Concepts.

SSPPDD007711110022

Automotive Trolleys

Customer: Automotive Conveyor Distributor Application: Automotive conveyor system Issue: The end user was experiencing a short life with the trolleys in their conveyor system causing them to spend large amounts of money and time to correct the problem. The original design was rubbing on a steel track causing the frame to wear due to the steel on steel friction Solution: The team at Caster Concepts was able to work with the distributor to double the life of the trolleys. The largest improvements were made in the design of the frame. The new design completely eliminated the steel on steel friction.

SPD000412

SSPPDD000000441122

Customer: Automotive Manufacturer Application: Heavy duty dollies Issue: Noise and Collision damage to trailers and other objects as well as low use life expectancy of the dollies Solution: A shock absorbing caster with a T/R compound wheel to quiet the process as well as a caster equipped with a sprocket to allow the caster to be steered The customer was having difficulty controlling the steering of the carts as well as the noise created by the carts. Caster Concepts was able to reduce the noise by using a shock absorbing caster as well as the T/R compound wheel. To correct the steering issue Caster Concepts welded sprockets to the yoke base to allow the casters to be steered and provide truer tracking of the dollies.

SSPPDD1100003311880022// 0033

SPD10031802/ 03

Customer: Automotive Assembly Plant Application: Mini Skillet system for Instrument Panel assembly line. Issue: The instrument panel mini skillet line is a highly automated assembly system that incorporates Automated Guided Vehicles and Robotic handling of parts. The skillets are considered tooling and are required to be precisely located in order to correctly interface with the automation. Material and debris on the floor could impact the locating of the tools as they moved through the manufacturing process. Solution: For consistency in locating the tool, Caster Concepts designed a guide wheel that would precisely engage the assembly track and assure proper location of the tooling throughout the assembly process. Track Brush wipers were incorporated into the Toe Guards to minimize the impact of foreign debris or objects interfering with the travel or location of the tool.

SSPPDD006611111100

SPD061110 Customer: Aerospace Manufacturing Application: Large finishing mandrel used in sanding section 41 (Cockpit, Galley, and Crew Quarters) of the Boeing 787 aircraft Issue: .Load was extremely fragile and heavy at 35,000 per caster. The floor had minor variations in surface height. Space limitations would not allow for caster shift while swiveling. Solution: Caster Concepts worked with the Boeing Offload Tool Design Engineering house to develop a double swivel caster to eliminate the castering effect of the tool as the casters went to swivel. A super high capacity precision slew bearing was used for the main swivel while the 35,000 capacity 99 series swivel section was used as the secondary swivel bearing. An Oscillating axle was incorporated into the design to allow for inconsistent floor surfaces.

SPD070606

Stubroller

Customer: Automotive Manufacturer Application: Skid conveyor drive wheel Issue: Supplier of the conveyor was no longer in business. Ford needed to repair and replace 180 drive wheels. Solution: Caster Concepts was supplied with a sample of the existing product to reverse engineer. The Stub Roller was designed by the Caster Concepts Engineering team to drop in without any modification. Caster Concepts used its 95A polyurethane to improve wear and life of the drive surface.

SSPPDD008800662200

SPD080620

Customer: Advanced Ground Systems Engineering Application: Jet Engine Transport Dolly Issue: Fragile Payload. Next Generation Engines were larger and heavier. This increase in size and load was causing competitor's product to experience swivel bearing failure. Warranty claims were very expensive as the engine dollies were in service around the world. Replacement casters had to be flown to the site to get the equipment back into service. The failure was causing the AGSE customer to lose confidence in the product. Solution: Caster Concepts sales and engineering team designed a 91 series kingpinless style, spring loaded caster that would survive the increased impact loads on the caster due to the heavier loads. Warranty claims have been eliminated and customer satisfaction has been restored.

SSPPDD0099111111110022 aanndd SSPPDD0099111111110033

SPD09111102/ SPD09111103

Customer: Conveyor Manufacturer Application: Conveyor System Issue: The manufacturer needed a domestic supplier to provide complete subassemblies. The customer was previously purchasing the product overseas and it was both expensive and time consuming for the product to by flown from Europe Solution: Caster Concepts was able to design, manufacture and deliver these products in less than 3 weeks. This saved the manufacturer time and money.

SSPPDD0088005511660011// 0022

SPD08051601/ 02

Customer: Material Handling Manufacturing Application: Transportation of Railroad Cars through the manufacturing process Issue: Extreme Loads each wheel had to carry 17,500 pounds and roll freely. Solution: Caster Concepts sales and engineering team worked with the customer to design and build solid steel single flange wheels on a stub axle. The axle /wheel assembly was mounted between pillow blocks for increased bearing capacity and alignment. One set of wheels was driven to power the rail car through the manufacturing process.

SSPPDD1100004400660011

Powder Coated Caster

Customer: Aircraft Component Manufacturer Application: Tow Tractors Issue: The current casters were very expensive and were not holding up to the application and environment at the plant. Solution: Caster Concepts spent time in the facility to fully understand the problem. By working in the plant CCI was able to understand how the caster was used and what the performance standards were required. With the help of the CCI engineering team the customer was presented with a product specially designed for them to meet all their needs. The product has been used at the facility for 4 months and the company is beginning to standardize the Caster Concept products for all their future caster needs.

SSPPDD009911110022

SPD091102

Customer: Design Implementer Application: Automotive assembly conveyor, power drive rollers. Convey the automobiles through the weld and final assembly processes. Issue: Source of supply is in Italy. Lead-time and ocean freight would not allow the customer to meet their customers' delivery expectations. Solution: Caster Concepts was approached to manufacture rollers within 3 weeks, to meet customer expectations. CCI engineering and manufacturing teams pulled together designed and manufactured the rollers on time so that they could be installed during plant shutdown, lessening the impact of the changeover.

1122330099--6666--2200

T/R Compound Wheel

Customer: Tire Manufacturer Application: Industrial Carts Issue: Build up of Green (raw) rubber in the manufacturing process Solution: Using a T/R compound wheel the pickup of debris on the wheel was significantly lessened The wheels previously placed on the carts were picking up debris making the tires out of round as well making the carts hard to push. With the use of the T/R compound wheel the debris picked up by the wheel was significantly decreased making the cart easier to push and keeping the wheel in round.

Before with Green tire build up

After 9 months with a T/R compound wheel