Mobile robots punish wheels differently than carts: continuous duty, constant acceleration, and tight tracking. Enter the robot weight, payload, speed, and runtime and this tool sizes the load capacity per wheel, the diameter, the tread, and the bearing for the duty cycle.
Size AGV and AMR wheels for continuous duty, not catalog conditions. Take the total weight on the load wheels, add a dynamic factor for acceleration and obstacles, and derate for round-the-clock running, so the rated capacity per wheel sits well above the static share. Use a low-hysteresis polyurethane tread for grip and low rolling resistance, a larger diameter for speed and thresholds, and precision sealed or maintenance-free bearings because you cannot re-grease a robot every week.
Results update as you type.
Per-wheel capacity = (weight ÷ load wheels) × 1.5 dynamic × duty factor
duty factor = 1.25 for 20+ hrs/day, 1.1 for 12-20, else 1.0
The dynamic factor covers acceleration, deceleration, and threshold impacts; continuous running adds a derating margin because heat and fatigue accumulate. Diameter scales with speed and floor roughness for ride and obstacle clearance. Drive wheels need a higher-traction, low-hysteresis tread so the robot tracks and does not waste torque to rolling resistance.
Planning guidance for selection. Validate against the robot OEM's wheel loads, your controls, and the specific tread and bearing ratings before finalizing.
Reviewed by Bob Camp, Director of Caster Sales, 45+ years in the caster industry. Updated June 14, 2026.
Sizing is planning guidance for AGV and AMR wheel selection. Validate against the robot OEM's wheel-load and tread requirements and your controls before finalizing. CasterHQ, Mansfield, TX · 844-439-4335.
