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CasterShoX™ - The Quiet Caster™ |
May 2007 |
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Caster Concepts is excited to introduce a radically new line of shock absorption casters. After two years of research and development and a quarter million dollar investment, Caster Concepts is launching its line of CasterShoX™ casters. Based on patented ultra-compact shock absorption technologies, the CasterShoX™ shock absorption core is entirely contained within the caster wheel. As a result, implementing CasterShoX™ products is as simple as changing wheels. Tested in industrial settings, CasterShoX™ casters reduce noise sources by as much as 15 dbA, a magnitude of reduction providing significant effect in reducing noise induced hearing loss. As a result, the National Institutes of Health funded R&D for this product.
CasterShoX™ casters are identical to conventional casters in appearance, shape and size. CasterShoX™ caster wheels come in two standard sizes, 6x2 and 8x2. Wheels can be supplied with high quality Caster Concepts polyurethane ranging from 70A to 70D. Solid, high strength, glass-filled nylon wheels are also available. CasterShoX™ wheels use a giant, super smooth 6013ZZ deep groove ball bearing which guarantees superior roll-ability and ergonomic factors.
The CasterShoX™ core provides ¾ of an inch of compliance and is currently manufactured with three varieties of spring stiffness. The light duty core has a 500 lbs capacity, the medium, 1000 lbs., and the heavy duty core, 1500 lbs. Compared to traditional spring loaded casters, CasterShoX™ casters are smaller, more economical and better performing because they inherently add damping to ensure stability. | |
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| CasterShoX™ Technology |
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| CasterShoX™ products are elastomeric based spring systems with a compact monolithic support structure which serves to guide the movement of the suspension system. The monolithic structure makes our products both robust and easily manufactured using conventional manufacturing processes. To correctly engineer our products, we use design methods employed in MEMS (micro-electro mechanical systems) design, where there are moving parts but no obvious joints or linkages, and thus very little wear occurs.
What differentiates CasterShoX™ products from conventional shock absorption products is compactness. This allows them to be completely housed within the wheels of any machinery without compromising their effectiveness to attenuate noise or vibrations. Retrofitting production equipment is as simple and inexpensive as exchanging existing wheels with our wheels which have the CasterShoX™ product assembled within. |
| CasterShoX™ Performance Testing |
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The performance of the CasterShoX™ 20 series casters have been measured and verified on custom designed laboratory test equipment. The results show a significant improvement in rejecting shock loads and vibrations. By using CasterShoX™ technology, the results show that the peak acceleration subjected to the wheel is reduced 5 times from 10G's to about 2G's. The data was generated using CasterShoX™'s 20 series platform embedded in an 8 inch outer diameter, 2 inch wide wheel, loaded at 500 lbs and run at 4 miles per hour over a ½ " obstruction.
Onsite testing using noise dosimeters clearly revealed a 10 dbA drop in the average noise level and more than a 15 dbA in the peak noise when CasterShoX™ are installed. Two similar line delivery carts, one equipped with conventional casters and one with CasterShoX™ casters, were towed through a manufacturing facility. A noise dosimeter was mounted onto the cart. Each cart was towed following a similar path. The approximate tow speed was 6 mph and the cart plus the load totaled about 2000 pounds. The noise dosimeter continuously recorded the noise produced by each cart for the duration of the testing. The results, graphed below, demonstrate a sizeable reduction in overall noise levels emitted by the transport cart using CasterShoX™.
Note that due to the logarithmic nature of the decibel scale, a 3 dbA drop in noise is considered to have removed one half the energy content of the noise source. Thus, a 10 dbA drop removes more than 90% of the noise energy; a 15dbA drop removes 97%. |
| Benefits of Shock Absorption Casters |
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The most compelling reason for implementing shock absorbers into casters is workplace safety related to hearing conservation. Extended exposure to higher decibel noise in the workplace is linked to hearing loss, stress, fatigue and is believed to result in a more hazardous work environment. While the federal noise level standard for continuous exposure is no more than 85dbA, it is common in many manufacturing facilities to be continuously exposed to noise levels above 95dbA. The most common source of industrial noise pollution is transport systems used to move components to various locations in the assembly facility. CasterShoX™ casters have been shown to reduce noise levels by as much as 15 dbA.
Safety, ergonomics and economics are all reasons to consider shock absorption functionality when purchasing or upgrading your caster system.
On top of noise reduction, the additional benefits of shock absorption casters include:
- Reduced wear on caster components thus extending the life of the caster product
- Reduced the vibrations transmitted through the cart and into the contents being carried, thus reducing the likelihood of damaging the carried cargo
- Reduced floor wear and damage
- Allowing all wheels to remain in contact with the traveling surface, providing better traction while also preventing uneven floor loading.
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| CasterShoX™ vs. Conventional Spring Loaded Casters |
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While CasterShoX™ casters function in a similar manner as conventional spring loaded casters, unique differences make CasterShoX™ a superior choice. CasterShoX™ products are based on an ultra compact design able to be built into almost any structure. In the picture below, the shock absorption system is placed directly into the wheel, without having to enlarge or change the shape of the wheel. As a result, CasterShoX™ wheels can be mounted onto existing caster rigs with a set of adapter plates. Delivery carts can be easily retrofitted with CasterShoX™ simply and cost effectively in minutes without the need to modify the cart structure. CasterShoX™ provides a clean, cost effective means of implementation.
The cost of a complete CasterShoX™ caster as compared with conventional spring loaded casters is approximately 30%-50% less. Considering the added cost savings of implementation, CasterShoX™ products become an impressive, inexpensive solution to some of the most challenging problems associated with cart delivery systems.
The CasterShoX™ shock absorption system is shown to reduce shock loads by 80% and reduce noise sources by 15dbA (95% noise energy is removed). The CasterShoX™ 20 series industrial duty shocks provide ¾" of travel, which allow it to absorb almost any shock load or vibration found in the factory environment. The CasterShoX™ spring system is based on an elastomeric spring which inherently provides damping. Unlike conventional coil spring loaded casters which have little or no damping, CasterShoX™'s inherent damping properties provide superior stability and noise rejection. |
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Which CasterShoX™ Products are Right for Your Applications? |
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Finding the right CasterShoX™ product requires an understanding of the speeds, loads and environmental conditions of the application. The 20 series CasterShoX™ core has three standard spring stiffnesses, each with a differing linear spring constant resulting in differing load capacity and noise rejection capability.
CasterShoX™ 20 series shock products have a maximum load capacity of about 2500 pounds. However, each different spring type has a recommended range of loading, a "sweet spot", - the loading range which allows the shock to work optimally in rejecting vibrations and reducing noise. For example, the number 9 spring has a recommended sweet spot range of about 750 pounds to 1500 pounds. The number 8 spring has a range of 500 pounds to 1000 pounds and the number 7 spring has a range of about 200 to 500 pounds. For applications where loads are less than 200 pounds, a lower series of CasterShoX™ product would be considered. A Caster Concepts engineer will work with you to find the optimal product for your application. Caster Concepts will recommend the correct spring strength based on both static and dynamic loading conditions. | |
I would close with the challenge to contact Caster Concepts for further information on how CasterShoX™ can be implemented into your work environment to significantly reduce white noise in the work place. Please visit us at www.casterconcepts.com, or call us at 1-517-629-8838 or e-mail us at castershox@casterconcepts.com.
CasterShoX™ - "The Quiet Caster"™
Sincerely,
Dr. William Dobbins
President
Caster Concepts | |
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