At Caster City, we understand that not all caster applications are created equal. In high-demand environments—where automated guided vehicles (AGVs) operate around the clock—durability, stability, extend battery life through reduced effort, and load-bearing capacity are non-negotiable. That is where dual wheel AGV casters come in. Built for continuous duty and high-capacity movement, these heavy duty casters are engineered to deliver unmatched performance in industrial settings.
Caster City’s dual wheel AGV casters are engineered first and foremost for battery-powered performance. With resist heat build up polyurethane that minimizes and conserves energy, these casters are ideal for automated guided vehicles (AGVs) operating in high-demand, 24/7 environments. While their ergonomic efficiency comes by default, it is their battery-saving properties, smooth motion, and resistance to thermal fatigue that make them stand out.
We will break down what dual wheel AGV casters are, how they are designed, and where they are most effectively used.
What Are Dual Wheel AGV Casters?
Dual wheel casters are exactly what they sound like: caster assemblies featuring two wheels side by side within a single housing. This design distributes weight more evenly than single-wheel casters and reduces point load stress on flooring. In AGV systems, this translates to smoother motion, increased stability, and better tracking—especially under heavy loads or on uneven surfaces.
One of the most important features of dual wheel casters is their differential action. In traditional casters, turning often creates “scuffing”. Scuffing refers to the friction and abrasion that occur when a wheel rotates without the ability for independent motion between wheels. This not only wears down the wheel faster but also damages flooring over time.
Dual wheel casters solve this problem with a split-wheel configuration that allows each wheel to move independently. This differential action makes turning smoother, even from a stationary position, and significantly reduces both floor wear and rolling resistance. It is a critical feature for AGVs operating in tight spaces, where precision and efficiency are essential.
But what truly sets Caster City’s casters apart—especially for battery-powered AGV systems—is their material performance. Our specialized polyurethane formulation is engineered to minimize heat build-up through reduced hysteresis. This avoids overheating and melting during long duty cycles, preserving wheel integrity and extending battery life. The result is a caster that delivers ergonomic efficiency by default, with reduced rolling resistance and low startup force, all while protecting critical vehicle components.
These casters are often used when load capacity, floor protection, or stability are a concern. In material handling, especially in facilities running AGVs 24/7, dual wheel configurations extend caster life and enhance vehicle efficiency.
If you are actively sourcing solutions, we recommend reviewing our Model 100 and Model 150 dual wheel heavy-duty casters—both designed to meet the rigorous demands of AGV systems and high-capacity environments.
Check out heavy-duty Dual casters for industrial AGV systems here. Check out our full range of heavy-duty casters here.
Load Capacity and Continuous Operation
Heavy-duty dual wheel AGV casters from Caster City are specifically engineered to support the intense demands of industrial automation. Key features include:
- High Load Capacity: Casters are built to handle from 3,200 to over 15,000 lbs per caster, making them ideal for AGVs in manufacturing, aviation, and logistics.
- Superior Load Distribution: Dual wheel configurations distribute weight more evenly than single-wheel casters, improving stability and reducing floor damage.
- Enhanced Stability: Particularly important for large AGVs and robotic systems that require smooth, balanced movement.
- Operational Longevity: The design reduces strain on AGV drive systems, enhances battery performance, and lowers the frequency of caster replacements.
Engineered by Caster City for 24/7 Performance
At Caster City, our dual wheel AGV casters are engineered with precision and built to perform. We utilize precision-engineered caster cores designed for durability in industrial environments and high-performance polyurethane treads featuring a crowned profile. This reduces floor contact, improves energy efficiency, and supports easier turning under heavy loads.
While many of the energy and durability benefits are covered throughout this guide, it is worth highlighting some of the lesser-known performance features:
- Press-fit bushings minimize axial play and help stabilize movement during rotation
- Reinforced mounting plates reduce vibration, particularly in high-speed applications
- Sealed bearing systems support continuous use with minimal maintenance, even under harsh conditions
These precision-built components ensure long-term performance and reliability—keeping AGVs and industrial material handling systems running smoothly around the clock.
Our crowned tread design also reduces the contact patch with the floor, minimizing friction and allowing smoother motion over minor surface irregularities. Combined with our low-hysteresis polyurethane, this prevents excessive internal heat buildup—maintaining wheel shape and stability even during long duty cycles. These properties reduce startup force, preserve battery performance, and extend caster lifespan.
Built for 24/7 Industrial Environments
Dual wheel AGV casters from Caster City are built to perform in nonstop industrial settings. Whether operating on the factory floor, in automated warehouses, or within aerospace facilities, our casters maintain consistent performance through continuous use.
Our casters are built to withstand:
- High-frequency rotation and maneuvering
- Exposure to extreme temperatures, oils, and chemicals
- Uneven surfaces and high-speed turns
This durability leads to lower maintenance intervals and reduced downtime, ensuring AGVs stay on task and in service.
Benefits for AGV Systems
In an AGV ecosystem, caster efficiency directly affects productivity. The right caster setup can:
- Improve tracking accuracy and maneuverability
- Reduce downtime due to fewer caster failures
- Enhance battery performance by reducing startup and rolling resistance through crowned polyurethane treads, hardened wheel materials, and precision-sealed ball bearings
- Deliver quieter, smoother rides that are ideal for precision-guided movements
- Prevent excessive internal heat buildup with low-hysteresis polyurethane, helping maintain wheel shape and energy efficiency during continuous use
Technologies like maintenance-free bearings, low-friction materials, and precision tolerances are all part of how Caster City casters help optimize AGV functionality.
Industrial Applications
Dual wheel AGV casters are essential in industries that demand constant mobility of heavy loads:
- Aerospace & Aviation – Ground support and maintenance vehicles
- Automotive – Assembly line automation and material transport
- Manufacturing – Pallet movement and industrial robotics
- Logistics – Heavy racking systems and continuous transport vehicles
These environments benefit from casters that can handle both static and dynamic loads, uneven surfaces, and uninterrupted cycles.
Common Mistakes to Avoid When Choosing AGV Casters
Selecting the wrong caster can cost more in the long run. Some common errors include:
- Underestimating load weight or floor conditions
- Choosing materials incompatible with chemical or heat exposure
- Overlooking the impact of rolling resistance on AGV battery life
At Caster City, we work directly with operations teams to ensure the right caster is selected the first time, helping our clients avoid costly replacements or operational inefficiencies. Contact Us to talk to our experts—they are here to help you find the perfect plate casters for your specific needs.
FAQs
What makes dual wheel casters easier to maneuver?
The side-by-side wheel configuration allows for differential action—meaning each wheel can rotate independently. This makes directional changes smoother, even from a stopped position, which is ideal for AGVs navigating tight spaces.
How does the caster design improve energy efficiency?
Caster City dual wheel casters use crowned polyurethane treads and precision sealed ball bearings to minimize rolling resistance. This means less force is required to initiate movement, conserving energy and extending AGV battery life.
What materials are used in your dual wheels, and why?
Our casters feature hard polyurethane for high durability and minimal wear. Aluminum hubs act as heat sinks, helping to dissipate heat during continuous operation—essential for high-speed, high-load environments.
Are they low maintenance?
Yes. Precision sealed ball bearings reduce friction and protect internal components from dust and debris, significantly lowering the need for servicing.
In which industries do dual wheels perform best?
From warehousing and automotive to aerospace and cleanroom environments, our casters are engineered to meet the unique demands of each setting—including corrosion-resistant options for sensitive applications.
Ready to Upgrade Your AGV System?
Whether you are designing a new AGV platform or optimizing an existing fleet, the right casters can make all the difference. At Caster City, we offer tailored dual wheel caster solutions engineered for heavy-duty industrial use.
As a manufacturer of AGV Heavy Duty Casters, Caster City provides custom-built solutions backed by decades of engineering and production experience. We specialize in crafting casters for high-performance environments where quality and reliability cannot be compromised.
Here is what sets us apart:
- In-house manufacturing for full quality control
- Expert support in product selection and custom specs
- Proven track record with industrial and AGV-focused clients
Whether you are upgrading an existing fleet or building out a new AGV system, Caster City has the capabilities and insight to help you move forward with confidence.
Get in touch with our team today to discuss your project requirements, request a quote, or explore our full range of AGV-compatible caster systems. Let’s keep your operations moving—smoother, faster, and longer.
Check out our full range of automated guided vehicles casters and heavy-duty casters at Caster City. Many of our models include convenient grease fittings and are built for demanding environments.
📞 Have questions? Call us at (800) 501-3808 or explore our Heavy Duty Casters today! Contact Us to talk to our experts—they are here to help you find the perfect plate casters for your specific needs.
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