Customer Background

The newly built intelligent production workshop of XX automotive parts manufacturing enterprise adopts a fully automated production line logistics system. Hundreds of AGVs (Automated Guided Vehicles), manual hydraulic handling vehicles, and heavy material transfer vehicles operate 24 hours a day between the production line and the storage area, forming the material lifeline of this’ unmanned factory ‘. However, in the early stages of production, the problems brought by traditional industrial casters gradually emerged, seriously restricting the further improvement of overall production efficiency.

The wheel challenge faced by industrial production lines

The intelligent manufacturing supervisor of the factory clearly pointed out during the project review meeting that the production line logistics system has put forward unprecedented high requirements for the walking wheels, and there are three core contradictions in the existing solutions:

1. The contradiction between cleanliness and noise in precision environments

Our production line involves the assembly of precision electronic components, with extremely high requirements for cleanliness and a quiet environment. Traditional rubber wheels leave difficult to remove marks on clean floors, and the operating noise exceeds 65 decibels, interfering with the operation of precision instruments. But completely silent soft wheels cannot withstand the pressure of heavy materials.

2. The contradiction between high-intensity use and maintenance costs

A single AGV travels over 50 kilometers per day and needs to complete thousands of precise start stop operations. Ordinary casters will experience severe wear or bearing damage within three months, leading to unplanned downtime. Frequent replacement not only increases the cost of spare parts, but also disrupts the production rhythm.

3. Dual requirements for precise positioning and ground protection

The production line requires that the precision error of material vehicle parking should not exceed ± 3 millimeters for the contact points. The existing wheels either damage the epoxy floor due to their hard material, or cause the parking position to shift due to excessive elasticity, making it difficult to achieve a balance between protecting the ground and precise positioning.

Specific requirements for polyurethane wheels in production line logistics

Based on the actual working conditions on the production site, we have summarized the five core requirements of smart factories for walking wheels:

Load bearing adaptability: It needs to meet different load requirements from 50 kilograms to 5 tons, and maintain stable rolling performance under various loads.

Dynamic precision control: Under high-frequency start stop conditions, the wheels need to have minimal rebound deformation to ensure the repeat positioning accuracy of the AGV.

Environmental friendliness: zero pollution, low noise (target value below 55 decibels), anti-static, meeting the environmental standards of Industry 4.0 workshops.

Durability economy: Under the intensity of 16 hours of daily operation and 350 days of annual work, the target service life is not less than 2 years.

Safety compliance: Compliant with industrial vehicle safety standards, possessing necessary flame retardant, chemical corrosion resistance and other characteristics.

Customized production line dedicated polyurethane wheel solution

We have formed a joint project team with the customer’s technical team to develop the “Intelligent Factory Series” polyurethane wheel system for different vehicle models and usage scenarios.

Solution 1: Gradient hardness polyurethane material system

We have established a scientific material selection system for different load-bearing requirements:

Lightweight AGV special wheels (carrying 50-300kg): Made of medium hardness polyurethane (80A-85A), optimized for the balance between elasticity and grip.

Special wheels for standard material vehicles (bearing 0.5-2 tons): Made of high hardness polyurethane (90A-95A) to ensure load-bearing stability while maintaining good shock absorption.

Special wheels for heavy-duty transport vehicles (carrying 2-5 tons): using ultra-high hardness formula (95A-98A) with reinforced wheel core design to eliminate any possibility of deformation.

Solution 2: Precision bearings and structural optimization design

To meet the high-precision requirements, we have conducted dual optimization:

Precision bearing system: Using Japanese NSK precision grade bearings, combined with special pre tension adjustment design, the radial runout is controlled within 0.05mm.

Anti deformation structure: The innovative six spoke support structure combined with thickened wheel rim design reduces lateral deformation of the wheel by 60% under heavy loads.

Solution 3: Environmentally friendly surface treatment technology:

We have developed patented technology to meet the demand for environmental friendliness

Non trace formula: using special polymer additives to completely eliminate chemical migration between the wheel surface and the floor material.

Silent technology: Add a microporous sound-absorbing layer between the wheel core and the polyurethane layer to reduce the operating noise to 53 decibels.

Anti static treatment: The resistance value of the wheel surface is controlled within the range of 10 ^ 6-10 ^ 8 Ω, meeting the electrostatic protection requirements of the electronic workshop.

Implementation effect and production value

After six months of comprehensive replacement, the factory conducted a systematic evaluation of the upgrade effect:

Positioning accuracy: The AGV’s repeated positioning accuracy has been improved from ± 5mm to ± 2mm, and the success rate of production line docking has been increased to 99.5%.

Environmental indicators: The average noise level in the workshop has been reduced by 8 decibels, and the cost of floor cleaning and maintenance has been reduced by 70%.

Service life: Under the same usage intensity, the polyurethane wheel has been running smoothly for more than 4000 hours, with only one-third of the wear of the original product.

Energy consumption performance: Due to reduced rolling resistance, AGV battery life has been extended by 15%.

Comprehensive production benefits

The upgrade of the walking system this time appears to solve the wheel problem, but in reality it is a fundamental optimization of the entire logistics system. The most significant change is that the maintenance team has shifted from ‘firefighting’ repair to preventive maintenance, saving over 200 maintenance hours per month

More importantly, “he added,” the stable operation of logistics equipment ensures the continuity of production pace. According to our calculations, the downtime of the production line caused by logistics interruptions has been reduced by 85%, which is equivalent to adding 30 hours of effective production time to the factory every month. Calculated based on the hourly output value of the production line, this improvement can create more than 5 million yuan in value annually

Financial analysis shows that although the one-time investment of polyurethane wheels is relatively high, the comprehensive savings in maintenance costs, reduced production interruption losses, and extended service life result in an investment return period of only 9 months.

Industry Insights and Future Prospects

The production line logistics system in the Industry 4.0 era is evolving from “functional satisfaction” to “performance optimization”. This case proves that the performance optimization of the walking wheel, as a basic component of logistics equipment, can generate systematic benefits far beyond expectations. Through scientific material selection and engineering design, polyurethane wheels can become the “invisible driving force” for improving the quality and efficiency of smart factories.

We will continue to deepen our cultivation in the field of industrial logistics, and use innovative material solutions to assist China’s manufacturing in transforming and upgrading towards intelligence and efficiency.

Provide basic logistics solutions for smart factories

YALIDE – Professional Supplier of Industrial Logistics Polyurethane Wheel Systems