Caster Wheel Integration Solution for Servo-Driven AGV

A system-level caster wheel solution engineered to balance load distribution, reduce servo stress, and extend AGV drivetrain lifespan.

1. Why standalone caster wheel selection is a hidden risk

In many AGV and AMR projects, caster wheels are treated as non-critical components, while engineering focus remains on servo motors and gearboxes. In practice, however, improper caster wheel design often becomes the root cause of system-level issues:

• Excessive load concentration on drive wheels (>60%)

• High current fluctuation during low-speed motion and in-place rotation

• Reduced chassis stability on uneven floors or under dynamic loads

Caster wheels are not accessories — they are part of the drive system.

2. System-level approach: integrating caster wheels into servo design

Instead of supplying caster wheels as isolated components, we engineer them as load-balancing elements within the servo drive and steering system.

Load distribution principle

• Drive wheels: 45%–55%

• Caster wheels: 45%–55%

This balance significantly reduces peak torque demand during start-stop and low-speed operation.

Direct impact on servo performance

Measured improvements in typical AGV applications include:

• Peak torque demand reduced by 8%–15%

• Low-speed current fluctuation reduced by 20%–30%

• Lower risk of servo overload and thermal stress

These benefits are achieved through mechanical optimization rather than control complexity.

3. Why standard industrial caster wheels fall short

Conventional caster wheels lack vertical compliance and transmit impact loads directly to the chassis. In contrast, AGV-oriented caster wheels feature:

• Articulated or floating structures for better floor adaptation

• High-load bearing arrangements for stable rotation

• Geometry matched to vehicle center-of-gravity height

Test results: Impact load transmission reduced by ≥25% under 1–2T payload conditions.

4. System synergy with servo drive and steering wheels

When combined with servo drive wheels or steering wheels, optimized caster wheels deliver:

• Improved low-speed stability

• Smoother in-place rotation

• Higher drivetrain lifespan consistency

• Reduced maintenance frequency

5. Lower total system cost, not higher component cost

The value of a system-level caster wheel solution lies in:

• Safer servo motor and drive sizing

• Extended gearbox and bearing life

• Shorter commissioning cycles

• Fewer field issues

Result: Higher AGV reliability without increasing control complexity.

6. Typical applications

• Warehouse logistics AGVs / AMRs

• Heavy-load transport robots (1T–5T)

• 24/7 industrial automation environments