Air Cushion Transport Systems, Wheel and Rail Transport Systems

Aero-Caster® applications

Aero-Caster® Applications

An innovative and cost-effective solution for moving heavy loads

AeroGo equipment uses a variety of Aero-Casters® or air cushions to literally float heavy loads on a virtually frictionless film of air. Aero-Casters® air cushions offer a clean, noiseless and safe alternative for the movement of heavy loads.

Reduced friction and omni-directional movement allow the operator to precisely place and align the load in a limited work space. The low profile of standard air cushion systems requires less than 70 mm clearance. Aero-Casters® will not damage floors and expensive reinforcement is usually not necessary.

 

Because we only use basic pneumatic components such as air regulators and hoses, our products are not only reliable, but will operate in most environments, with minimal maintenance as compared to other conventional material handling methods.

 

The Aero-Caster® Principle

Minimum 3 or more Load Modules™ (typically 4) are placed under the load around the centre of gravity and connected to a control console. The Load Modules™ are solidly supported on landing pads to protect the Aero-Caster®’s torus bag from being crushed when the load is at rest.

 

When air is being applied into the Aero-Casters®, the torus bag inflates, creating a seal with the floor. When all Aero-Casters® have been sealed to the floor, the pressure is being raised thereby lifting the load.

 

When the pressure in the chamber is sufficient to offset the load’s weight (surface area x pressure), the pressure is slightly raised allowing the air to gradually escape between the flexible torus and the floor. The load is literally floating on a thin, nearly frictionless film of air of 0,08 to 0,13 mm, allowing the load to move omnidirectionally in complete 2D freedom.

Unlimited load

Unlimited Load Weights

The AeroGo air cushion systems utilize the efficiency of fluid film technology to actually float heavy loads on a near-frictionless film of air. Aero-Casters® distribute the load weight over a greater surface than with rollers or wheels, spreading any stress over a wider floor aria.

Whether you’re moving 500 kilogram or 5.000 tons, we’re ready to engineer and manufacture the special system for your unique needs – or to offer you the finest range of standard load moving equipment in the world.

We’ve built computer guided stepconveyors for complete ship sections, specialized quick mould & die changers and inspection units for tools from 5 to 150 ton. We’ve also launched cargo ships. We’ve moved underground a 180-ton drill head and moved the largest telescope mirrors. We’ve transported 250 ton aerospace rocket boosters and 5.200 ton concrete caissons. We’ve made the largest 180 ton AGV.

Low Investment Cost

Every load is moved economically on Aero-Caster® air cushions. The wide range of Load Module™ models offer no limit to load lifting capacities. Compared to conventional moving methods, you will get lower initial costs; lower operating costs and increased productivity.

Other benefits of air cushion equipment

Maximum Material Handling Efficiency – AeroGo’s advanced Aero-Caster® products can be used again and again.

Simple Operation – Anyone learns in minutes

Low Friction – Material Handling with minimum effort. Minimizes the force required to move the load. Move most loads manually, without the need for tow vehicles, winches, cranes, etc.

Easy Turning – Omnidirectional. No added resistance when turning or changing direction. Easy especially in tight corners and spaces.

Thin Profile – Easily insert under load, eliminating the need for a separate jacking system. Most have less than a 2-inch height, when deflated.

Low & Safe – Minimal lift provided when inflated, keeping load move low to the ground. Works great in minimal clearance situations.

No Floor Damage – Load weight spread over a larger area, eliminating point loading and extending the life of your floors.

Industrial Strength – Rugged construction and durability – thoroughly tested & proven under severe load conditions. Aero-Caster® air bearings hold-up under high stress & hard use.

No Vibration – Sensitive loads moved without damage.

Whatever the weight, whatever the distance, AVT is there to move it!

Standard air cushion systems

Load Module Systems™

Load Modules™ and Load Module Systems™ utilize the efficiency of the air bearing to lift and move loads of any size, shape or weight. Load Module Systems™, one of AeroGo’s most versatile products, are made up of four or more Load Modules™. Positioned under any load shape, they provide lift and support wherever it’s needed. With Load Module™ capacity ranging from 1/2 ton to 60 tons each, Load Modules™ are available to move anything that isn’t anchored down. The Load Modules™ thin profile allows AeroGo’s products to be easily inserted under most equipment, eliminating the need for a separate jacking system, as well as providing vertical lift when inflated. Unlike caster wheels, which resist changes in direction, Load Module Systems™ are truly omnidirectional, requiring no additional force to change direction.
Load Module Systems™ are lightweight and easily positioned under a load. Control Consoles provide individual pressure regulation to compensate for unequal load distribution. Because Load Modules™ float on a nearly frictionless film of air, loads can often be moved manually, without the need for tow vehicles or winches.

 

For additional info, see the brochure:Load_Module_brochure_UK.pdf

 

GAPMASTER™ Aero-Caster®

The GAPMASTER™ Aero-Caster® is especially developed for the smooth movement of loads over gaps and steps in the floor surface. Originally developed for theatre applications to move stage sets and theatre seating, the GAPMASTER™ Aero-Caster® can also be effective in autoclave loading, moving dies over t-slots, moving loads into and out of elevators or onto flush-mount scales, lift tables, turntables and pit covers.

 

A perforated membrane encloses the Aero-Caster® GAPMASTER™ and meters the rate of air flow. Upon encountering a gap, rapid outflow of air is prevented by the metering action of this membrane. Since the load is actually floating over the surface, the potential for floor damage is substantially reduced.

 

For additional info, see the brochure:Gapmaster_UK.pdf

 

Aero-Pallet™ Systems

Aero-Pallets™ are designed to easily move and precisely position heavy loads on a nearly frictionless film of air, eliminating operator strain and damage to load or floor. Their flexibility is ideal for Lean-Flow manufacturing applications as well as production support and testing. Catalog models handle loads from 230kg (500 pounds) to 14 tons – and engineered solutions can address almost any load or configuration. Optional handles, throttle controls, and no-load wheels make it even easier to operate the Aero-Pallet™ loaded or unloaded. AeroGo products are reliable and virtually maintenance free – all you need is air.

You will move loads less expensively than the total operating cost of other load moving systems. Aero-Pallets™ replace or assist expensive rollers, overhead conveyors, cranes or forklifts, creating a better workspace for assembly personnel. Their omni-directional advantage allows individual assemblies to be moved in any direction in or out of the line – for testing, repairs or special steps. Aero-Pallets™ are available with fixed or automatic chocks for super-easy handling of round paper or steel rolls and are easily modified for deck tooling or lift tables. They are ideal in cleanrooms and hazardous or explosive environments because the only power required is compressed air.

 

For additional info, see the brochure:Pallets_Brochure_UK.pdf

 

AirShuttle™

The AirShuttle™ is a variant of the Aero-Pallet™ and includes 4 Aero-Casters®, a T-handle, fingertip controls, a guide wheel, and no-load wheels.The AirShuttle™ packages the most popular options with a super easy control handle, making it the easiest and most capable Aero-Pallet™ ever made. The base model is rated at 2,5 tons and is available from stock in a variety of sizes. The AirShuttle™ replace or assist expensive rollers, overhead conveyors, cranes or forklifts, creating a better workspace for assembly personnel. Their omni-directional advantage allows individual assemblies to be moved in any direction in or out of the line – for testing, repairs or special steps. They are ideal in cleanrooms and hazardous or explosive environments because the only power required is compressed air.

 

 

For additional info, see the above brochure of the Aero-Pallet™.

 

Aero-Plank™ Systems

Aero-Planks™ are designed for use with loads having minor variations in width but large variations in length. Set-up is easy and fast, requiring only one air hose connection.
Aero-Planks™ can be used in combinations of two or more to move long complex machines such as printing presses or mail sorting machinery. Using Aero-Planks™ avoids time consuming and costly work interruptions, and machine disassembly and reassembly.

Aero-Planks™ are available in varying lengths and widths to accommodate almost any load configuration.
Aero-Planks™ are frequently used in flexible manufacturing systems and assembly lines to replace cumbersome track, rail or in-floor conveyor systems. Aero-Planks™ offers unprecedented flexibility with omnidirectional movement and can free-up cranes and forklifts for other tasks. Uneven loads can be automatically adjusted using a single air pressure regulator in combination with built-in active flow controls.

 

For additional info, see the brochure: Planks_brochure_UK.pdf

 

Rollmaster™

AeroGo’s Rollmaster™ literally floats heavy paper rolls on a thin film of compressed air, helping paper processors and web printers save time, manpower and money. Our patented technology makes it possible for one person to easily maneuver heavy loads without the use of a forklift or floor track system. As little as one kilo of push can move a 1000 kilos of weight, so one person can smoothly transport, rotate and precisely position even the largest and heaviest paper rolls.

The Rollmaster™ uses standard shop air to instabtly float and move heavy rolls in any direction. It is equipped with a fixed, full width handle, guide wheels, pressure regulator and on/off ball valve. An optional handle mounted air control is available. With the AeroGo Rollmaster™, you get easy, dependable, omnidirectional roll control without hazardous fumes and noise. AeroGo also manufactures a complete line of custom-engineered models for soft paper rolls and other roll moving applications.

 

For additional info, see the brochure: rollmaster.pdf

 

Rollmover™

AeroGo’s Rollmover™ literally floats heavy paper rolls, metal sheet coils and cable reels on a thin film of compressed air. Our patented technology makes it possible for one person to easily manoeuvre heavy loads without the use of a forklift or floor track system. As little as one kilo of push can move 500 kilograms of weight, so one person can smoothly transport, rotate and precisely position even the largest and heaviest paper, plastic, sheet metal or coil rolls.

Just place one Rollmover™ section under each end of the roll, and use standard shop air to instantly float and move the roll in any direction. When the move is complete, the Aero-Casters® quickly deflate, and the light weight sections are carried to the next job. With the AeroGo Rollmover™, you get easy, dependable, omnidirectional roll control without hazardous fumes and noise.
And, with no moving parts to wear out, the Rollmover™ requires little or no maintenance.

 

For additional info, see the brochure: total_rollmover_EN.doc

Engineered Projects on air cushions, wheels or rails

Air Cushion Transport Systems

AVT frequently gets requests to move extremely heavy loads or to position them in a very precise way. In practice the air cushion transporters are for these applications the pre-eminent means provided that the floor is smooth, sealed and level. We have a broad know-how and many years’ experience in the field of air cushion technology: Air-cushion transporters go from automated guided vehicles (AGV’s), over transporters for aerospace or shipyard applications, to coil & reel transporters, lift tables, turntables, gantry cranes, tool changers etc
Air cushion transport systems are also often used in dust-free environments (clean room).

 

Air cushion systems offer the unique advantage that they cause no floor damage because they float on a frictionless film of air. Furthermore, air cushion systems are omni directional and are easily manoeuvrable in narrow spaces. Finally the transporters on air cushions are ‘clean systems’ because they use compressed air and are consequently also suitable as a transport method in explosive spaces.

Wheel Transport Systems

 

According to the requirements of the customers and the given operational circumstances AVT designs and produces also wheel transporters to move internally heavy loads. These transport systems are made entirely in house. Wheel transporters are in principle not dependent of the floor conditions as a result of which they can be used both inside and outside.

Rail Transport Systems

Also rail transporters are entirely designed and built in house and are produced according to the requirements of the customer and the operational circumstances. The rail transporters are very use friendly certainly when it comes to driving forward and backwards. Rail transport systems can move also heavy charges with a low actuation power.

 

Specifications Fluid Film Floor Surface

Fluid film floor surfaces

The surface is part of the Aero-Caster® system

The proper surface creating perfect working conditions for air film technology is sealed, smooth and plane. Most floors in modern workshops apply to these requirements, like steel-troweled concrete floors with an epoxy based coating as a protection against wear and to prevent dust. The expansion joints should be filled with an elastic load-bearing compound.
The surface needs to be non-porous, to ensure that the torus bag can inflate between the load and the floor.
To maintain a fluid film between the torus bag and the floor with a minimum of air the surface needs to be smooth. Near frictionless movement can be obtained on this fluid film.
To prevent load from sliding on this near frictionless fluid film the surface needs to be plane, without slopes.

New floors : New floors for fluid film transport should be constructed according to concrete planarity tolerances DIN 18202, part 5, line 4.
The surface will be steel-troweled, protected by a sealer and possibly covered by an epoxy coating.

Joints : Expansion joints should be filled with an elastic compound. We recommend a rubber-like urethane with a Shore-index of approximately 94. To ensure that the joint can be filled properly, a width of no less than approximately 10 mm is recommended. Air loss is minimal when the filler is slightly curved upwards.
The smoothness of the surface has a major influence on the air requirements. The rougher the surface, the more air will be required to maintain the air film. On a rough, sandpaper-type surface increased friction can cause more wear on the air cushion material.

Surface-Index : The required air-volume needed to move a specific load, on different surfaces with different friction levels, can be determined using the index table. The standard reference Index No. 1 applies for a polished plate glass surface. Index No. 3, for example, means that rated air supply will be multiplied by three.

Floor charge : The specific charge on the floor when using air-bearings is limited due to its larger surface, flexibility and reduced net weight compared to transport means on wheels. Delicate surfaces such as parquet, linoleum, varnished hardwood or surfaces with floor heating can support heavy loads on air-bearings without risk of damage. In any case the admissible floor load must be respected, although also in this respect air cushions offer advantages.

Non-sealed surfaces : Air escaping trough a porous floor can result in air-bearings not being able to build up enough pressure to carry the load or even maintain an air film to float on. A non-sealed concrete floor is porous and allows small amounts of air to escape. Also sealed surfaces can “leak” trough cracks, blisters, scaling or joints. These can easily be repaired with filler, tape or overlays.

Old floors : Floors for fluid film transport should be constructed according to concrete planarity tolerances DIN 18202. To apply to these requirements it may be necessary to cover the floor with a coating. To ensure a good adhesion for this coating it may be necessary to grind, polish or scrub the surface previously.
In particular floor coverings like vinyl, parquet, linoleum and tiles ought to have a good and air-thight adhesion to the concrete floor. The smallest crack can let air go under the covering and can cause the covering to separate from the floor.

Undulations and slopes : Due to their flexibility air-bearings will comply to undulations with height differences up to 2% of the caster diameter.
Large undulations can be considered as slopes. Due to reduced friction a load on air film will go down the slope. The force needed to redirect a load on a slope can be calculated as follows :
F = tg a x G (don’t forget the dynamic forces!)

In similar cases the load must be secured by means of AeroGo drives or other mechanical systems.
Steps can be negotiated by means of a ramp. In which case the above mentioned values must be considered.

Cleanliness : For a flawless and lasting operation of air-bearings a clean floor is needed.
On a well-prepared surface wear is almost non-existent. Small objects like sand grains, wood chippings, cigarette butts etc. will be blown away by the escaping air film. Paint stains, oil stains, truck tire marks etc. on the other hand will impair the surface quality, stick to the Aero-Caster torus and increase the air consumption. Large and sharp objects such as nails, screws or steel chippings stuck on the floor will damage the torus and should be removed.

Temporary overlays : One time moves, such as relocation of machines, can be done on practically every surface by covering the track with sheet metal overlays. (See “Manual for Load Module Systems”).

Air-Jack Systems

Air-Jack Systems

The Air-Jacks – especially designed for industrial and jacking applications – are ideal for intensive use in difficult conditions, due to their robust form. As the Air-Jacks weigh less and are easy to carry, they are also simple to handle and allow for problem-free storage, transport and use. Thanks to the low profile of Air-Jacks, a play of only 25 mm is required, and within only a few seconds they will fully inflate.

 

For more info see the brochure: Aero-Jacks_EN.pdf

Accessories Air Cushion Systems

Control Console

With the control console or teh control box the air supply to the air bearing (Aero-Casters®) is regulated. The 4-box serves 4 aircushions , the 6-box serves 6 aircushions and the economy box is used for the smaller Aero-Casters® up to 15". AeroGo’s fixed mount Control Console is available for applications which require AeroGo equipment to be permanently attached to a load.

 

Storage Cart

Storage carts provide an easy and secure method for storing and transporting AeroGo’s Load Module Systems™.
Heavy Duty storage carts are equipped with large heavy duty caster wheels and a hose reel for ease of handling a supply hose.

 

Hose Reel with Supply Hose

AeroGo offers an extensive selection of manual, spring and power assisted hose reels.

 

Safety Fuse

Designed for use with air supply hoses, the safety fuse prevents potentially dangerous hose whips and possible operator injury should the hose accidentally become disconnected, severed or broken.

 

Slide Mount

The Aero-Caster® slide mount provides an easy method to remove the air cushion for inspection or repair, while loaded or unloaded.

 

Water Caster

Water Casters use water instead of air cushions in order to supply the bearings with sufficient pressure.
Water Casters are being used for extremely heavy applications when water flooding the floors is not a problem such as dry docks and shipbuilding and when applications for water evacuation and recuperation are being anticipated such as caisson building up to 5200 tons or stadium gallery moves.
The supply of water in case of large quantities is easier and more cost efficient with standard water pumps.

 

Air Drive

The Air Drive is a steerable air-motor powered drive for moving and positioning heavier loads. Three models available with rated drawbar pull ranging from 300 kg to 980 kg. The Air Drive can be mounted in a permanent way to the load structure or it can be uncoupled.

 

Guide Wheel

Need a bit more directional control for your air caster or air bearing products on uneven, slight slopes or when tight positioning is crucial? AeroGo Guide Wheels provide added directional guidance for our air floats and bearings.