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All measurements indicate the wheel diameter by the tread width.

The below capacity ranges indicate the working (dynamic) load that each caster will support. A safety factor should be included in your formula to determine your required load rating per caster.

W/(C-1)=R W is total weight needed to move. C is total number of casters required. R is ideal load rating, with safety factor built in. Divide the total load weight by one less caster than you will use to safely determine load rating.

Plate dimensions shown are overall mounting plate size.
When replacing existing casters, select the closest plate size and verify bolt-hole compatibility.
BHP = Bolt Hole Pattern, shown under each plate.

BHP: 1-3/4″ × 2-7/8″, slotted to 3″
BHP: 1-3/4″ × 2-7/8″, slotted to 3″
BHP: 1-3/4″ × 2-15/16″ slotted to 2-3/8″ × 3-3/8″
BHP: 1-3/4″ × 2-15/16″ slotted to 2-3/8″ × 3-3/8″
BHP: 2-5/8” X 3-5/8” (Slotted to 3” x 3”)
BHP: 2-5/8” X 3-5/8” (Slotted to 3” x 3”)
BHP: 2-7/16" x 4-15/16" slotted to 3-3/8" x 5-1/4"
BHP: 2-7/16" x 4-15/16" slotted to 3-3/8" x 5-1/4"
(3″ Wide Casters), Industry-Standard
(3″ Wide Casters), Industry-Standard
BHP: 3-3/8" x 5-1/4" slotted to 4-1/8" x 6-1/8"
BHP: 3-3/8" x 5-1/4" slotted to 4-1/8" x 6-1/8"
BHP: 4-1/8" x 6" slotted to 4-1/2" x 6-1/8"
BHP: 4-1/8" x 6" slotted to 4-1/2" x 6-1/8"
View All • 21 Plate Sizes
View All • 21 Plate Sizes
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Casters for AGV and AMR: Sealed Precision, Kingpinless, Continuous Duty

Industry hub for AGV + AMR + robotics

Casters for AGV and AMR: Sealed, Kingpinless, 24/7.

AGV (Automated Guided Vehicle) and AMR (Autonomous Mobile Robot) fleets are the fastest-growing segment of the industrial caster market — 200,000+ units deployed globally in 2024, 25% YoY growth. Caster spec for AGV/AMR is fundamentally different from manual cart spec: continuous duty, sealed bearings, kingpinless, no field service window.

TL;DR · Procurement Brief

If You Skim Nothing Else

Sealed precision ball bearings — mandatory.
Field re-lube is impractical on continuous-duty robots. Standard ball bearings fail in months from grease loss. Sealed precision is the only option.
Kingpinless construction required.
Dynamic loads from acceleration, braking, and turning under load shear conventional kingpins within 6-12 months. No exceptions on AGV duty cycles.
Polyurethane 95A on cast iron or steel core.
Hard durometer for lower rolling resistance under dynamic load. Soft compounds wear too fast on continuous-duty robotic platforms.
No re-lube schedule, no inspection access.
Replace as a unit on documented schedule. Visual inspection during preventive maintenance only.
Match OEM specs exactly on replacement.
AGV/AMR fleets are tuned to specific caster characteristics (rolling diameter, hardness, friction). Generic replacements alter robot navigation behavior.

Application Areas

Warehouse Pick-Pack AMR Fleets

Mobile inventory shelving, totes-to-person robots. Loads 500-2,000 lb per caster. Spec: 6 inch polyurethane 95A on cast iron, sealed precision ball, kingpinless, 4 x 4-1/2 plate.

Manufacturing Tow AGV Platforms

Line-side cart movement, kitting, sub-assembly delivery. Loads 1,500-5,000 lb per caster. Spec: 8 inch polyurethane on iron, sealed tapered roller, kingpinless, 5 x 6-1/4 plate.

Heavy-Duty Industrial AGV (Up to 15,400 lb)

Engine, transmission, battery pack transport in automotive and energy. Spec: 10 inch poly on forged iron, sealed precision ball or tapered roller, kingpinless construction with maxi-duty rig.

Hospital and Healthcare AMR

Linen, supplies, pharmacy delivery robots. Loads 200-800 lb per caster. Spec: 5-6 inch food-grade or medical-grade polyurethane, sealed precision ball, stainless or zinc-plated frame, quiet operation priority.

Cleanroom AMR (Semiconductor, Pharma)

AMHS and pharma material handling robots. Loads 200-1,000 lb per caster. Spec: ESD-safe or low-outgassing wheel, sealed precision ball, electropolished stainless, ISO-class qualified.

Key Requirements

AGV/AMR Aftermarket Replacement Spec

Most AGV/AMR fleets reach caster-replacement age before they reach end-of-life. Aftermarket replacement is the procurement reality.

  • OEM caster matching: AGV manufacturers tune navigation to specific caster characteristics. Replacement must match wheel diameter, hardness, and rolling friction within OEM tolerance.
  • Service interval: typical AGV caster life is 18,000-30,000 hours under continuous duty (~3-5 years). Spec replacement before failure to avoid mid-shift downtime.
  • Inventory strategy: stock 1-2 spare casters per AGV minimum. Replacement is faster than rotation through the OEM service channel.
  • Documentation: track caster lot numbers and install dates per AGV unit. Helps diagnose navigation drift and isolate caster wear from other issues.
  • Polyurethane formulation: most AGV OEMs spec a specific hardness (typically 92A or 95A) and rebound. Substituting a softer compound increases rolling resistance and reduces battery life.

Application Spec Sheet

Application Environment Load/Caster Wheel Diameter Bearing Frame/Plate
Pick-pack AMR (warehouse) Continuous 500-2,000 lb Poly 95A on cast iron 6" Sealed precision ball Kingpinless 4 x 4-1/2
Tow AGV (manufacturing) Continuous 1,500-5,000 lb Poly 95A on cast iron 8" Sealed tapered roller Kingpinless 5 x 6-1/4
Heavy AGV (auto, energy) Continuous 5,000-15,400 lb Poly on forged iron 10" Sealed tapered roller Kingpinless 6-1/2 x 7-1/2
Healthcare AMR Continuous 200-800 lb Med-grade poly or TPR 5" Sealed precision ball Kingpinless stainless
Cleanroom AMR (semi/pharma) Continuous 200-1,000 lb ESD-safe poly low-outgas 5" Sealed precision ball Kingpinless electropolished
Common Mistakes

Spec Mistakes to Avoid

01
Replacing AGV casters with standard industrial casters. AGV navigation tuned to specific wheel diameter, hardness, and friction. Generic replacements alter robot path accuracy and battery life.
02
Specifying open or shielded ball bearings. Field re-lube impossible on continuous-duty robots. Sealed precision ball is the only acceptable spec.
03
Soft polyurethane (85A) on heavy AGV platforms. Compresses under dynamic load, increases rolling resistance, drains battery faster. Use 95A minimum on AGV/AMR.
04
Skipping kingpinless on tow AGV. Dynamic loads from turning under tension shear conventional kingpins within 6-12 months.
05
Inventory of zero spare casters per AGV. Mid-shift caster failure stops the line. Stock 1-2 spares per AGV unit.
Engineer Tips

Engineer Selection Tips

  • Match OEM spec exactly on replacement. Wheel diameter, hardness, plate size, bearing type. AGV manufacturers tune navigation calibration to these characteristics. Substituting outside tolerance alters path accuracy.
  • Track caster install date per AGV unit. AGV caster life is 18,000-30,000 hours under continuous duty. Replacement scheduling beats reactive replacement that causes line stops.
  • Spec to the harder durometer. Polyurethane 95A rolls easier under dynamic load, lasts longer on continuous duty, and reduces battery consumption versus softer compounds.
  • Sealed precision ball is the default — always. No exceptions on AGV/AMR. Open bearings fail in months. Tapered roller for loads above 2,500 lb per caster or where turning under load is continuous.
FAQ

Common Questions

Can I replace AGV casters with standard industrial casters?
Only if the spec matches exactly. AGV navigation calibration depends on consistent rolling diameter, hardness, and friction coefficient. Substituting a 90A wheel where the OEM specified 95A will alter robot path accuracy and battery consumption.
What's the lead time on AGV-spec casters?
Standard kingpinless sealed-precision casters in stock ship same or next day from CasterHQ. Custom OEM-spec replacements (specific durometer, branded compound, special bearing) run 2-4 weeks. Plan AGV PM schedules around lead time.
Do AGV casters require special bearings?
Sealed precision ball bearings minimum. Tapered roller for higher loads (above 2,500 lb per caster) or where the AGV turns under load (forklift-AGV hybrids). No standard ball, no plain bearings, no Delrin.
What about ESD-safe AGV casters?
Required for AGV/AMR in semiconductor fabs, electronics handling, and ESD-controlled assembly lines. Static-dissipative polyurethane (10^6 to 10^9 ohm) on grounded stainless frame. Specify ESD at order, not at installation.
Can CasterHQ match a Hamilton or Mecalux AGV caster?
Yes for most major AGV OEMs. Send the OEM caster part number or specification (wheel diameter, durometer, plate size, bearing type, capacity) and an engineer matches the closest CasterHQ stock equivalent within 4 business hours.
How long do AGV casters last?
18,000-30,000 hours of continuous-duty service is typical. That equates to 3-5 years of single-shift operation, 1-2 years of 24/7 operation. Plan replacement before predicted failure to avoid mid-shift line stops.
Can CasterHQ match a specific AGV OEM's caster spec?
Yes for most major AGV manufacturers. Send the OEM caster part number, wheel diameter, durometer, plate dimensions, and bearing spec. Engineer matches the closest CasterHQ stock equivalent in 4 business hours.
Are there AGV-specific certifications I should look for?
No industry-wide AGV caster certification exists. Practical requirements are: continuous duty rating (ANSI B56.5 for AGV operational safety references the supporting components), sealed precision bearings (no field service window), kingpinless construction (eliminates the dominant failure mode), and match to OEM nav-calibration spec.

Spec'ing for This Application?

Engineer review within 4 business hours. Application-validated spec, compliance documentation, lead time confirmation.

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