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The excellent performance and diverse application scenarios of heavy duty iron core polyurethane wheels
In the fields of industrial automation and logistics, heavy-duty iron-core Polyurethane Wheels, with their unique "rigidity and flexibility" design—a composite structure of a high-strength iron core and a high-performance polyurethane coating—have become core components supporting the stable operation of heavy-duty equipment. From port container handlers to intelligent warehouse stackers, from mining equipment to medical precision instruments, these "industrial wheels" are driving efficiency upgrades across multiple industries with their superior performance.
Core Structure: A golden combination of Iron Wheel core and polyurethane coating
- High-Strength Iron Wheel Core
Material: Crafted from high-quality cast iron or high-strength steel, precision-cast or forged, they ensure the wheel body resists deformation and fracture under heavy loads.
Design: The iron core surface is galvanized or spray-coated for enhanced corrosion resistance, making it suitable for harsh environments such as humidity, acidity, and alkalinity. Some high-end models feature thickened hubs or five reinforcing ribs (such as the super-heavy-duty gantry crane wheels). The four wheels can support a maximum load of 5tons, meeting the needs of large equipment mobility.
- Polyurethane Overmolding
Material Characteristics: Polyurethane elastomer combines the elasticity of rubber with the strength of plastic, with a Shore hardness range of A10-D80, offering a balanced balance of wear resistance and shock absorption. Its wear resistance is 3-5times that of rubber, and its tear strength is more than 2 times greater.
Process Advantages: Vulcanization bonding technology tightly bonds the polyurethane to the core, achieving a peel strength of≥8N/mm, eliminating the risk of debonding. Controlled surface roughness reduces rolling resistance and improves operating efficiency.
Superior Performance: Five Key Advantages Support Tough Industrial Demands
- Superior Load Capacity
The composite structure of the iron core and polyurethane gives the wheel exceptional compressive strength. The single-wheel load capacity ranges from 100kg to 5tons, easily handling the demands of moving heavy equipment such as forklifts, stackers, and gantry cranes.
- Extremely Wear-Resistant and Durable
The polyurethane coating maintains low wear even under high-frequency, high-load conditions, resulting in a lifespan 2-5times that of ordinary rubber wheels. For example, in e-commerce warehouses, where forklift wheels travel over 30kilometers daily, polyurethane wheels can achieve a lifespan of over two years.
- Impact Resistance and Vibration Absorption
The polyurethane's elastic modulus absorbs high-frequency vibrations, reducing equipment shake. In cold chain logistics, it maintains its elasticity even at low temperatures (-25℃), preventing damage to goods caused by vibration.
- Quiet Operation
Low rolling noise meets the needs of noise-sensitive environments such as hospitals and libraries. Medical bed wheels feature an antibacterial polyurethane tread to further reduce the risk of cross-infection.
5. Chemical Resistance
Polyurethane offers excellent resistance to oils, fats, acids, bases, and solvents, making it suitable for use in industries such as food processing, chemicals, and metallurgy. For example, food conveyor rollers must meet FDA certification, and polyurethane prevents oil penetration, ensuring food safety.
Diverse Applications: Mobile Solutions Covering All Industrial Scenarios
- Logistics and Warehousing
Core Equipment: Electric forklifts, stacking cranes, automated guided vehicle (AGV) robots, and automated conveyor lines.
Applications:
High-speed sorting systems: Wheels must withstand frequent start-stop shocks, and polyurethane's fatigue resistance ensures long-term stable operation.
Cold chain warehouses: A low-temperature polyurethane formula prevents wheel embrittlement, and an electric heating device prevents icing and jamming.
- Industrial Manufacturing
Core Equipment: Mobile workstations on production lines, heavy-duty machine tools, roller conveyors, and industrial carts.
Applications:
Automotive production lines: Drive wheels must withstand heavy loads, including engines and vehicle bodies. Polyurethane coatings reduce scratches and extend equipment life.
Metallurgical Industry: Wheels must withstand high-temperature iron chips reaching 150℃. Specially formulated polyurethane or ceramic coatings ensure stable performance.
- Special Environments
Airports/Terminals: Forklift wheels require high grip to prevent slipping on wet surfaces. The polyurethane tread pattern design improves the coefficient of friction. Construction sites: Wheels must withstand impacts from sharp objects like gravel and rebar, so thickened, rubber-coated iron-core polyurethane wheels enhance protection.
- Public Facilities
Medical Equipment: Hospital equipment and instruments require quiet operation and vibration reduction. Polyurethane materials meet medical-grade environmental standards and are non-toxic and odorless.
Selection and Maintenance: Key Strategies for Extending Wheel Life
- Selection Key Points
Load Matching: Select the wheel's load capacity based on the total weight of the equipment, allowing a 30% safety margin.
Environmental Adaptability: For high-temperature environments, choose heat-resistant polyurethane (long-term operating temperature≤120℃); for humid environments, choose a galvanized iron core.
Surface Conditions: For uneven surfaces, choose wheels with wide treads to improve maneuverability.
- Maintenance Guidelines
Regular Inspection: Regularly inspect wheel tread wear, iron core corrosion, and bearing clearance, and replace damaged parts promptly.
Cleaning and Maintenance: Avoid oil and chemical corrosion. Apply anti-rust oil to protect the iron core after cleaning.
Lubrication Management: Relubricate deep groove ball bearings with lithium-based grease every two months. For high-temperature environments, use molybdenum disulfide lubricant.
Heavy-duty iron core polyurethane wheels, with their core advantages of high load capacity, strong wear resistance, and wide compatibility, have become a standard component of industrial mobile equipment. From efficient sorting in logistics and warehousing to the silent movement of medical equipment, from high-temperature heavy loads in the metallurgical industry to low-temperature stability in cold chain logistics, the deep integration of performance and scenarios is driving industrial automation towards higher efficiency, lower costs, and greater sustainability. In the future, with breakthroughs in materials science and intelligent technology, this "industrial wheel" will continue to unleash tremendous energy.
Dongguan carsun Caster Co.,Ltd
We are a professional manufacturer of industrial caster wheels.
We can produce different types of casters according to your requirements.
We are the experienced Caster Wheel supplier.
OEM ODM etc are all welcome.
Packing/color/size/material are all available.
For more product information, please contact us.
Website:www.carsuncastor.com
Email: sales@casterchina.cc
Phone/WeChat/Skype:+86 18929102151
WhatsApp:+8613622621956
www.carsuncastor.com
Factory address: No. 38 Industrial North Road,Shangjia Dazhou,Wanjiang Street,Dongguan city, Guangdong Province, China