Air Caster

SUBMITTED TO: Prof. B.B. SATPATHY Er. SANTOSH PANDA Dept. of MECHANICAL ENGINEERING

SUBMITTED BY: JITENJAYA PATTNAIK REGD NO: 1001217095 7TH SEM, MECH. ENGG

PKACE, BARGARH

CERTIFICATE

This is to certify that Mr. JITENJAYA PATTNAIK, a student of 7thsemester, mechanical engineering of Padmashree Krutartha Acharya College Of Engineering bearing Regd. No. 1001217195 has taken active interest in preparing his seminar report in

“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)

ACKNOWLEDGEMENT

THE SATISFACTION THAT ACCOMPANIES THE SUCCESSFUL COMPLETION OF THE TASK WOULD BE INCOMPLETE PEOPLE

WHO

WITHOUT MADE

THE IT

MENTION

POSSIBLE

OF &

THE

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

INTRODUCTION Casters are small wheels designed to make furniture, appliances& machinery move from one place to another easily. In air 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 british hovercraft 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 can’t meet your requirement, more hoses are workable.

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 686mm×686mm×50mm. 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 of 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.

AeroGo air caster equipment uses a variety of air casters to literally float heavy loads on a virtually frictionless film 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 bearing systems 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 lean manufacturing setups, reduced worker compensation claims, and improved operator environment to industrial corporations of any size or type especially in light of today’s 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 even large seating sections found in theatres or convention centers. This is just a small sample of typical applications.

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 or dollies, 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 system to 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 drop in 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.

Connecting compressed air to a Hovair System is 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 pneumatically with compressed air. Generally the compressed air needs 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!

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 valves should face the outside of the footprint's shape. Here is a typicalair caster system footprint after assembly, an air line hose with quick-disconnect fittings, and a selection of connections and fittings you are likely to find in an air bearing system. Each air caster module will have a pre-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 load module, 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 on all Hovair Systems air caster kit systems.

With all air hoses connected to the load modules, the air line hoses should be connected to the remaining hardware which will 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 casters in 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 in order 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.

OPERATION OF AIR BEARINGS / CASTERS WHEN ENERGIZED WITH A COMPRESSED AIR SUPPLY, THE FOLLOWING SEQUENCE OF EVENTS TAKES PLACE 1.) The circular reinforced rubber 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 – that’s 10 times better than conventional wheels or casters

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 fabricreinforced air bearings used by some competitors.

PRODUCTS

AIR CASTER AIR BEARINGS Air bearings eliminate friction to allow movement of 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 air bearings are made with a tough wear resistant urethane diaphragm, giving superior performance

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 CASTER NO.

SIZE (IN.)

CAPACITY (LBS.)

AIR INLET (FPT)

AIR FLOW (CFM)

LIFT (IN.)

AC-10

10 ½ x 10 ½

1000

¼

8

½

AC-14

14 ½ x 14 ½

2000

3/8

12

5/8

AC-18

18 ½ x 18 ½

5000

3/8

16

¾

AC-22

22 ½ x 22 ½

7500

½

20

1

AC-30

30 ½ x 30 ½

15,000

½

32

1 1/8

AC-34

34 ½ x 34 ½

20,000

¾

36

1¼

AC-46

46 ½ x 46 ½

36,000

¾

50

1½

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.

HOW AIR CASTER PLATFORMS WORK? Like air 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 force that 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 TRANSPORTERS Mould and die handling  Transfers between crane bays  Assembly line movement of product or subassemblies o Heavy construction o Heavy electrical o Automotive  Moving loads into test cells, coordinate measuring machine rooms 

Moving machine tools, process equipment  Assembly fixtures 

Heavy load Air Caster platforms (capacity to 140,000 pounds)

General purpose Air Caster platforms (capacity to 6,000 pounds)

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 

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: o Heavy steel construction for a firm, steady support deck o Fully adjustable throughout lift range o Easy height adjustment with foot valve up/down control o Easy 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 include pneumatic 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 to unit  Permanently lubricated bearings 

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 provided for 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 Load – Spent fuel storage casket

Solution –To maneuver this spent fuel storage cask into temporary storage, AeroGo engineers designed a convenient solution using the AeroGo transporter system.

ROLL HANDLING Using just standard shop air, AeroGo’s Rollmover and Rollmaster II make it possible for a single person to easily floatheavy paper rolls, metal sheet coils, cable reels and other similar loads on a thin film of compressed air without the use of bulky overhead cranes, forklifts, rails or floor track systems. This

unique air caster technology provides a reliable and easy-to-use alternative for your roll movement needs.

POWER GENERATION Weight – 80,000 lbs. Load – Feed water heater

Solution – When a customer needed to replace a feed water heater in a power plant, the customer identified AeroGo's load module 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 load weight across the floor.

TRANSFORMER MANUFACTURING Weight – 250 tons Application –Power distribution transformers

Solution– A customer needed to transport power distribution transformers up to 800 tons through the manufacturing process and in and out of vapor phase ovens.

VEHICLE ASSEMBLY Weight – 40,000 lbs. Load – Recreational vehicles

Solution – A customer needed to move a recreational vehicle through the assembly process. AeroGo engineers used

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 

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Aerospace Weight – 220 tons Load – Solid rocket segment

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 

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EFFICIENCY – Precise positioning to mandrels without damage caused by traditional material handling equipment methods. USER-FRIENDLY– Provides clean and ergonomic roll handling lifts, and can be customized with T-bar handle, noload wheels or Tie Bar pair for added stability. SAFE TO USE– With 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 that’s needed is a source of compressed air; a smooth sealed surface such as concrete, epoxy coated, 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:  Operates on plant air  Low friction force  Clean and quiet operation  Omni or 4 directional motions  Low surface loading  Precise positioning  Gently move sensitive  Protects floor finish loads  Eliminates need for fork  Safely move and control trucks or overhead cranes 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.

CONCLUSION

Air is the most abundant substance on the world, it is available everywhere and free of cost. So why don’t 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.

REFERENCE 1.

www.wikipedia.org

2.

www.google.com

3.

www.howstuffworks.com

4.

www.aircastercorporation.com

5.

www.wikihow.com

6.

www.airfloat.com

7.

www.aerogo.com

8.

www.hovair.com

EXPERT REVIEWS

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