Wheel Block System

In the world of heavy-duty cranes, material handling, and rail-guided transport systems, industrial travel wheels play a critical role. They enable precise, smooth, and reliable movement of machines or assemblies along a defined track or surface. As the direct interface between the machine and its running surface, travel wheels carry loads, absorb impacts, transmit driving forces, and maintain directional stability.

Their design, materials, and maintenance directly influence a system’s overall efficiency, service life, and safety.

Among many solutions available, Demag wheel systems stand out as highly engineered, modular systems capable of covering a wide load range — from light-duty conveyors to ultra-heavy cranes.

Technical Principles and Key Components

A complete industrial travel wheel system typically consists of several core elements:

1. Travel Wheel (Tread & Profile)

Made of materials such as spheroidal graphite cast iron, polyurethane (Hydropur), or polyamide (nylon).

Rim design: double-flanged, single-flanged, flange-less, or central-flanged.

Profile shapes: flat, concave, convex, V-type, or crowned.

Optional surface treatments include hardening, coating, or rubberized treads.

2. Bearing and Bearing Housing

Roller, ball, or tapered roller bearings designed for high load and long life.

Grease-lubricated or maintenance-free sealed bearings.

Precise alignment within the housing ensures low friction and smooth operation.

3. Housing / Wheel Block Frame

Made from cast iron or welded steel plates with five-sided enclosed geometry.

Prevents ingress of dust, water, and debris.

Machined mounting faces enable multiple installation orientations (top, side, or pin-mounted).

4. Drive or Transmission Unit (for driven wheels)

Gear reducers (helical, bevel, or offset designs).

Couplings, torque arms, and electric motor integration.

Synchronized control and braking systems.

5. Guiding and Auxiliary Components

Guide rollers and track interfaces for precise directional control.

Shock absorbers and vibration dampers for smooth operation.

Optional sensors for wear, temperature, or vibration monitoring.

Demag Wheel System Series Overview

According to Demag’s product literature, its wheel range covers multiple modular series — each optimized for specific load, speed, and environmental conditions.

DRS / DRS-M Wheel Block System

Covers a wide load range: 2.75 t to 40 t per wheel.

Highly modular system with multiple wheel types and customized designs.

Five-sided enclosed housing for excellent dust and moisture protection.

Patented asymmetric housing design allows wheel replacement without realignment.

Various connection interfaces: top, pin, end, or side mounting.

Available with laser alignment tools, wear indicators, and optional guide roller kits.

→ Ideal for bridge cranes, gantry cranes, and heavy transport systems requiring precision alignment and easy maintenance.

Key Advantages and Technical Highlights

From the analysis of these series, several engineering strengths emerge:

Modular and Flexible Design:Multiple standardized mounting faces and accessories allow easy integration into various structures.

High Structural Integrity:Fully enclosed, five-sided housings protect against dust, debris, and moisture, ensuring long-term reliability.

Maintenance-Friendly Construction:Asymmetric housings enable quick wheel replacement without re-alignment.

Laser alignment and wear markings simplify setup and inspection.

Material Optimization:Spheroidal graphite cast iron provides toughness and wear resistance.

Hydropur polyurethane treads offer elasticity, noise reduction, and shock absorption.

High-temperature or corrosion-resistant materials are available for harsh environments.

Heavy Load and High-Speed Capability:Precision manufacturing and advanced bearing systems ensure smooth operation even under dynamic loads.

Global Service and Engineering Support:Demag offers CAD models, selection software, and worldwide technical support for all wheel systems.

Seamless Integration with Drives and Controls:Fully compatible with Demag’s gearboxes, motors, and control systems, allowing precise motion control and optimized performance.

Applications

Industrial travel wheels are used across many industries and systems, including:

• Bridge and Gantry Cranes – frequent start/stop cycles, lateral forces, and high shock loads.

• Rail-Guided Transport Systems – such as container gantries, transfer carts, or tunnel transport systems.

• Heavy Material Handling Platforms – in workshops or assembly lines for molds, dies, or machinery transport.

• Harsh Environments – foundries, steel plants, or chemical facilities requiring high temperature and corrosion resistance.

• Automated Logistics and AGVs – where precision movement and low noise are key.

• Retrofit and Upgrade Projects – replacing old travel mechanisms with modular wheel block systems for improved reliability.

Selection Criteria and Design Considerations

When selecting an industrial travel wheel system, engineers should evaluate:

Load Capacity and Safety Factor:Determine static and dynamic load per wheel and apply suitable safety margins.

• Track Type and Tolerance:Consider rail width, flatness, and joint quality — this affects flange design and wear.

• Travel Speed and Acceleration:Wheel inertia, drive power, and braking requirements must be balanced.

• Operating Environment:Evaluate temperature, dust, humidity, and exposure to chemicals.

• Service Life and Maintenance:Bearing lifespan, lubrication method, and wheel replacement procedure affect total cost of ownership.

• Installation and Alignment:Use laser alignment and precise machining to ensure smooth operation.

• System Compatibility:Verify integration with motors, gearboxes, control units, and safety systems.

• Cost and Lifecycle Economics:Compare initial cost, operating efficiency, and long-term maintenance expenses.

• Redundancy and Safety:In critical systems (e.g., long-span cranes), redundant wheel sets enhance reliability.

Example Case (Conceptual)

A manufacturing plant plans a 60 t heavy-duty transfer car traveling at 1.5 m/s with a turning radius ≥ 10 m.

An optimal solution might include:

DRS-M wheel blocks for their modularity and high load range.

Double-flanged cast iron wheels for track alignment, with polyurethane-coated wheels on selected units for vibration damping.

Integrated gear reducers and motors with torque arms to minimize radial loads.

Laser alignment tools for precise setup.

Sensors to monitor wear, temperature, and vibration.

Five-sided enclosed housings with built-in track cleaning and shock absorption.

This setup ensures high operational reliability, reduced maintenance, and extended service life.

Conclusion

Industrial travel wheels — particularly advanced modular systems like those from Demag — are vital for modern heavy-duty motion solutions. They combine mechanical precision, material engineering, and ease of integration to deliver reliable, long-lasting performance across industries. Selecting the right travel wheel system involves not just load and speed, but also a deep understanding of environment, maintenance, and lifecycle costs — ensuring that every move counts toward productivity and safety.