Overview
Automated guided vehicles (AGVs) and robotics depend on caster performance more than many buyers realize. Selection errors increase vibration, noise, wear, and failure rates.
This article identifies the most common mistakes and shows how correct selection improves uptime.
Common Selection Mistakes
- Choosing casters rated only for load and not duty cycle
- Selecting wheel materials without accounting for continuous motion
- Using general-purpose casters instead of AGV-specific designs
- Ignoring bearing and swivel life requirements
Error Modes Comparison
| Error Mode | Cause | Impact |
|---|---|---|
| Low duty rating | Rated for manual use | Premature wear |
| Incorrect wheel material | Wrong vibration tolerance | Tracking errors |
| Poor bearing rating | Low continuous rating | Excessive maintenance |
| Insufficient swivel life | Not designed for continuous turns | Binding and noise |
Operational Consequences
- Increased unplanned downtime
- Higher maintenance labor
- Reduced throughput
- Higher lifetime cost
These issues can reduce AGV uptime and increase operational risk in automated environments.
Reference the full 2026 Industrial Forecast for broader context on automation trends and mobility component failure patterns.
How to Fix Selection Errors
- Match duty cycle rating to actual continuous motion
- Select wheel material based on vibration and surface conditions
- Use AGV-specific caster designs where possible
- Choose bearings and swivels rated for continuous use