New Article - How to Measure a Caster Stem

We've heard from our customers that one of their biggest frustrations is ordering the wrong caster stem. You know how it goes, you get the box from the delivery driver, open it up, they look right.  Then you take off the old ones and they don't fit. You know how this story ends.

So to help, we've created a new guide to help get the right measurements, the first time. Using two common tools, an adjustable wrench and a ruler, you will be able to get the right dimensions of a grip ring or threaded stem (by far the most common types).

If you have any questions, don't hesitate to let us know.

A late addition…

Having just completed the caster mounting series, it came as quite a surprise when we saw this caster.  Shown on right is a  kingpinless caster with a 2” x 2” angle stem for mounting.  The caster had to be designed as shown to reduce the mounting height of the caster as much as possible.

The caster is composed of a 71 series rig, welded to a 2” x 2” angle iron section, that has been punched for mounting.  The wheel is 2-1/2” diameter glass filled nylon wheel.  In order to distinguish the caster from older stock, which has a higher overall height, and is therefore incompatible with this caster, it has been zinc-dichromate plated.  Zinc-dichromate provides the brass/gold finish shown.

Got an odd application, let us know.  We love working on them.

Caster Mounting - Part 6 - Top Plates

Without a doubt, a top plate is the most common means of mounting a caster. From small to large, light to heavy, top plates provide the most secure and convenient method of mounting. A top plate doesn't need explanation to understand how it works, a plate with holes that one puts bolts through.

With that being said, there is some nuance to getting the right bolt hole pattern. This is critical in replacement applications, the wrong pattern will mean having to return and exchange the caster or having to drill new holes on existing equipment. A typical bolt hole pattern reads as follows:

• 2-5/8" x 3-5/8" slotted to 3" x 3"

This means that the holes on the outside most part of the plate are 2-5/8" x 3-5/8" then slotted to the inner part at 3" x 3". The graphic to the right illustrates this well. Some top plates do not come with slotted holes, others have holes slotted in other directions. Generally speaking, a caster series, with the exception of furniture casters, is defined by its top plate size.

Top plate casters are available in furniture, institutional, industrial and kingpinless types. If you need help finding the right top plate for your application, don't hesitate to contact us.

Caster Mounting - Part 5 - Round Stem

Round stems are by far the simplest stem design around. It is literally a piece of round stock riveted into the kingpin of the caster. They actually are not that different from a grip ring stem. Instead of using a locking ring to hold it in place, it is a simple compression fit.

But, they are very rare. Normally a grip ring or threaded stem is used due to their positive locking. We do not recommend using a round stem, if at all possible. Contact us to discuss your options.

Caster Mounting - Part 2 - Threaded Stems

A threaded stem is quite simple, it's a round piece of metal with a cut thread, as the name implies. The threaded stem is more broadly used, yet less common than the grip ring stem; because threaded stems come in nearly any size, metric or standard, small to large diameter, fine or coarse thread, the options are many. Threaded stems are available standard on institutional and furniture casters, and through special order on industrial casters.

A threaded stem provides a more secure mounting than any other stem mount. Where grip ring and grip neck stems can become loose over time, the threaded stem, short of the stem shearing, will remain in place. A fair comparison between grip and threaded stems is nails to screws.

In order for a threaded stem caster to be attached to equipment, the equipment must have a tapped bore to accept the stem. For the most part adding the tapped bore is part of manufacturing the equipment. However, certain materials, by nature, don't accept a thread very well. In these instances certain adapters are available. Pictured to the right is an adapter for wood, it is installed by drilling a hole to the appropriate outside diameter of the adapter, then the adapter is hammered into place, secured by the webbing off the flange.

Threaded stems, as stated above, are available in nearly any size.  Standard size threaded stems are generally 1/4" to 1/2" coarse.  However, stems as large as 1" in diameter are readily available, although they are special order and can have a slightly longer lead time. 

Noting the disadvantages, installation time is increased as compared to grip style stems. Further, manufacturing time of the equipment may be increased due to the bore and tap requirements.

In summary, the threaded stem provides a near universal method of caster mounting.  The increased manufacturing costs can be a problem, but the secure mounting may offset this.  If you have questions about your application, please don't hesitate to contact us.

Caster Mounting - Part 1 - Grip Ring Stems

The grip ring stem is quite possibly the most common caster stem in use. Used predominately on consumer and commercial office and shop equipment, this stem provides rapid installation and quick change. Grip ring stems are typically available on furniture and institutional casters.

The stem works by utilizing a piece of round steel with a channel machined in the top portion. The machined channel is then fitted with a locking ring, either brass or steel. This ring is slightly larger than the stem itself. The mounting sockets are made to match the stem, with a recessed race in the top portion of the socket, so as to accept the locking ring from the stem. When inserted the locking ring expands into the recessed race, locking the stem into position. The mechanism provides positive retention, without impeding removal should it be required.

Grip ring stems are most commonly used on molded plastic components, wherein the socket can be made an integral part of the equipment. This reduces overall cost and makes for faster manufacturing.

These stems can also be used in equipment made of round or square hollow tube. Pre-sized sockets are available for common mill sizes. Socket inserts are quite inexpensive and provide an easy and simple way to make equipment mobile that otherwise would not be.

There are some noted disadvantages of using a grip ring stem caster. Capacity being the first. Generally speaking, 200-lbs is about the limit of a grip ring stem. This is in part due to the nature of the casters it is sold with, and that it is a narrow distribution of the load. The load being focused on the kingpin entirely. Secondly, over time, it is possible for grip ring stem casters to come loose. So these are not generally indicated for abusive or rough applications.

All in all, the grip ring stem provides a great solution for many mobility applications. Its rapid installation and change-out, high availability, and the variety of casters fitted with grip ring stems, make it a tempting choice for designing a mobile product.

If you have questions regarding your mounting options, please contact us.

So many ways to mount a caster

There are many different ways to mount a caster to a piece of equipment, generally there are six industry standard methods, pictured below. In the coming week we will discuss the advantages and disadvantages of each and why it should be used on equipment. The posts are directed at design minded people, but could prove an interesting read regardless. If you need help deciding, please don't hesitate to contact us.

From left to right: Top Plate, Grip Ring, Expanding Adapter, Grip Neck (Wood) Stem, Threaded Stem, and Plain (Round) Stem

Now spin....

In most situations, standard casters, like our institutional, industrial and kingpinless line provide adequate maneuverability. But, when hitting your mark is more important than anything else, super maneuverable casters are required.

A tri-swivel caster, with a trade name of StageMaster, by Darnell-Rose, is a perfect solution for rolling equipment around a live stage.  They work by utilizing multiple swivel sections.  Pictured to the right is a custom application using our 75 Series swivel section, welded to a custom plate.  The wheels are Swivel-Eaz by Aubin.  This provides the ultimate in mobility in the smallest possible space. Low-profile and high capacity, these quiet casters allow for props and scenes to be placed with precision, in a hurry.  Because, as we all know, "The show must go on!"

We are able to custom fabricate nearly any size or capacity tri-swivel caster, fitting nearly any equipment.  Contact us for more information.

All locked up

Standard caster brakes, like face and cam styles, work pretty well for many situations. They hold the cart in place, but if it gets nudged it may move, as the swivel section of the caster is still free to roam.  For lighter duty applications, enter the 34 Series. 

The 34 Series Institutional Casters feature the same top plate, wheels and overall heights as the 32 Series, however the swivel models are available with a Total Lock Brake.   A Total Lock Brake, as the name suggests, completely stops a swivel caster from moving in any direction.  They work by integrating a face brake and a swivel lock.  On our 34 Series a forked piece of metal is pushed up against the swivel section, which is notched to accept it.  When engaged, the swivel section is prevented from moving, and the wheel, because of the face brake, is arrested. 

Take a look at the selection available on our site. 

Plain for me, Thanks!

We're probably guilty of this... but, a lot of advertising and marketing effort is spent promoting new and hyped up casters.  Whether it be a new bearing, rig, or wheel, they certainly generate a lot of buzz, but for most people, they just don't fit.   Remember, for many applications in the medium duty range, our standard 44 series casters work just great!  Made of quality steel, iron, plastics and polyurethanes, they are an excellent value at a great price! 

If you have any questions, please don't hesitate to contact us.

Towing the line

Tugger and trailer operations are incredibly efficient.  They allow a facility to reduce their requirements for forklifts, reduce cross aisle traffic, protect pallet rack and add a level of safety.  We like the idea, so much so, that a few years ago we wrote a white paper on this very subject.  However, towed trailers move at much higher speeds, typically under heavier loads, than a cart that is hand pushed. 

The capacity requirement is easily met by increasing the diameter of the wheel, sometimes the tread width too.  But, that's simple enough.  The real tricky part is that higher speed.  The average person walks at about 2 to 3 miles per hour, and that's a pretty good pace.  A tugger can easily do 7 miles per hour.  This creates a whole new set of problems for the caster. Typically, we recommend using a heavy duty rig, kingpinless or otherwise, in our 60, 65, 75, or 76 series.  The wheels should be slightly resilient, thus providing some grip against the floor.   Most important, the right bearing needs to be used.  Roller bearings will fail at 7 miles per hour, without even really trying.  The preferred bearing is a tapered roller bearing, sometimes referred to as a thrust bearing.

Tapered bearings come with their own problems, though.  They are hard to push and pull, requiring a large amount of force to start the cart rolling.  If carts are to be moved by tugger and by employees, you can use a precision ball bearing in the towing operation. 

The best thing to do is call on the experts at Conveyer & Caster - Equipment for Industry. Our staff is well versed in the complexities and solutions for towing applications.  Let us know how we can help.

Don't Throw Out that Old Dresser

This morning, on the Dallas Examiner's website, Cindi Hinton posted a great article! Old dressers, that may be headed for the trash, have a chance to be re purposed, even upcycled, as great slide-away storage bins.

Hinton Writes:

Have an old broken dresser that has seen its better days and headed for the trash? Well think again! Take out the drawers, put casters on the bottom, and put a nice drawer pull on front. Now you have a new easy to use storage area for under the kid’s beds or other numerous places around the house. Use to store toys, crafts or just about anything. You can even paint or decorate any way you wish.

Using small furniture casters, most likely with top plates, would be an easy an inexpensive way to take on this project. Consider the 12 or 14 series, they perform well over carpet, are very durable, and are a great value

Ease your burden

Injuries to workers are costly, time consuming and painful for the worker and the company. An easy way to help avoid those injuries is to use a caster that's designed for push-pull applications.

Many wheels can work well for this application, but the new new PMB wheel in a 71 series rig is absolutely perfectly suited. The wheel, a donut shape polyurethane on aluminum wheel with a precision ball bearing, provides single point of contact on the floor and in the bearing. This intern leads to reduced start and push forces. The kingpinless rig turns smoothly under load and without load.

Available in 5, 6, and 8 inch sizes, these casters are perfect for nearly any application. The rest of our 71 series lineup provides a wide array of wheel options, from phenolic to polyurethane, plastic to forged steel.

Slide on over

From time to time, a truly unique design comes about in the world of casters and wheels. Normally, new designs focus on bearings, tread, brakes, etc. However, once in a great while, not to sound punny, someone really does reinvent the wheel.

Rotacaster, Ltd., of Newcastle, NSW, Australia, has done just that. The Rotacaster is an "omnidirectional" wheel. No swivel rigs are needed, the wheel, in a rigid mounting can go in any direction. Each wheel is covered with directional rollers, allowing the wheel to move from side to side. The design solves many problems, including failure of swivel sections, ergonomic issues, and tight turning situations.

The wheels can be used for so much more than just casters. Applications include hand trucks, appliance dollies, conveyors, furniture dollies, and much more.

Contact us to learn more.

Welcome to the Team!

We'd like to welcome Michael, our newest product and design engineer to the Conveyer & Caster - Equipment for Industry family. His new and abstract influence will surely help us in providing the most innovative and revolutionary casters.

His training is from the University of Cleveland School of Design. Here he learned that there are no wrong ways to design. His innovations have earned many awards and distinctions.

Michael, welcome to the family!

Picture courtesy of failblog.org

Kingpinless? That sounds made up

It is. Well, the word at least, it doesn't appear in Websters. But that's okay.

For the longest time, swivel casters were made of three basic pieces, a yoke, a plate and a kingpin. Between the yoke and the plate is the bearing race, the kingpin holds it all together. It works well enough for most applications. They can be quite heavy duty, but then it starts getting expensive, using tapered bearings or hot forged steel. The kingpin has always proved to be the single greatest point of failure in a caster.

Now, we have "kingpinless". A kingpinless caster, as the name implies, doesn't have a kingpin. It's actually a simpler design, when examined closely. The swivel bearing actually holds the yoke and the plate together. This makes the caster especially strong, as the surface area for thrust loads is increased, exponentially. In the end, they are cheaper to manufacture, take less parts, and break less often. It's a killer combination.

To take a look at some kingpinless casters, click here.