Air Film Technology is poised to revolutionize the process of moving heavy loads by harnessing the power of compressed air. This technology, developed in Great Britain in the 1950s, formed the basis of the design of the well-known hovercraft and is still changing the way the industry handles load today.
Air Film Technology significantly lowers friction by moving a heavy object by placing a thin cushion of air between the object and the floor. This will enable the movement of objects ranging in weight from a few hundred kilograms to over 100 tons to occur without friction, allowing them to move safely and efficiently.
In this article, you will understand what air film technology is, how it works, its types, and its advantages. You will also learn how this frictionless method has revolutionized the world of moving heavy equipment.
Understanding Air Film Technology
The technology is a frictionless method of moving heavy loads. Here is the detail regarding the use of air for moving heavy machinery from one place to another within industries and warehouses.
Basic Concepts
The basic concept involves propelling heavy loads away on the floor. In which controlled compressed air at 100 PSI pressure is used to inflate an air caster or air bearing. Sometimes, a continuous flow of air is used to form an air film between the floor and the heavy load.
There are small openings or exhaust holes on the surface of an air caster that facilitate the use of compressed air in moving loads of up to 100 tons. The air cushion is 0.003 to 0.005 inches (0.08 to 0.13 mm) thick, resulting in nearly zero friction.
It is essential to note that with air film systems, an individual can move a load of 5,000 pounds (2,268 kg) with a force of only 50 pounds (22.6 kg). This represents a tiny fraction (1%) of the total weight of the load and is definitely less than the 225 Newtons (approximately 50 pounds) of pushing force recommended by OSHA as safe for manual handling.
Core Components
Air Film Technology systems would typically entail:
- Air Casters or Air Bearings
Flat, closed diaphragms (typically made of polyurethane) are used to distribute compressed air evenly.
- Compressed Air Supply
Air compressors are used in standard warehouses (or industries) that provide 40-50 psi to keep the lift.
- Hoses and Valves
These are the parts that control and regulate the flow of air.
- Load Modules
They are made of steel or aluminium and consist of a platform around which the object to be moved is placed (round or square).
Historical Background
The history dates back to the 1930s, when Toivo Kaario first invented air casters in Finland. After that, hovercrafts were invented in Great Britain in 1950. The invention came into industrial use in the 1960s. Today, the use of air film technology has become commonplace in every industry.
How Air Film Technology Works
It starts with the introduction of compressed air in an air caster or air bearing. When the air is released into the bearing diaphragm, it is released through specially designed exhaust holes and passes between the load and the floor.
The surface of the floor must be smooth, free from any cracks or damage, which will be reflected into the diaphragm. After that, the air pressure accumulates up to the point when it pushes the diaphragm and forms a stable air cushion.
Friction is minimized by up to 99% once the load is floating, enabling it to move across the floor without creating any noise. A standard system employs four or more air casters to spread the weight evenly, thereby balancing and ensuring safety during movement.
Types of Air Film Technology Systems
- Air Casters (Air Bearings)
Air Casters are the most dominant kind of air film system. They are round or square modules of steel or aluminium, each with a diaphragm of air bearing. These casters have the capacity to lift loads ranging from 1 ton to more than 100 tons, depending on the design. Air casters are best used in the transportation of heavy machinery, sensitive equipment, or oversized loads where forklifts or cranes are inapplicable.
- Air Film Movers
Air Film Movers are fully fledged systems characterized by air casters installed on modular platforms, along with hoses and control valves. A micron-level film forms between the load and the floor. They are capable of moving industrial equipment, aircraft parts, or medical equipment weighing between 10 tons and 600 tons with remarkable accuracy in a narrow area.
- Heavy-Duty Systems
In extreme applications where loads exceed 100 tons, heavy-duty air film systems are employed, utilizing reinforced materials and higher air pressures. These systems are typically applied in the aerospace, shipbuilding, and power generation sectors, where large machinery needs to be moved securely and effectively.
- Modular Kits
Modular kits comprise more than one air caster integrated into a single system. Users can also utilize a small kit and add new modules as the load capacity increases. For example, a four-station aluminium kit has the potential to be upgraded to support loads of 50 tons or more easily by adding more casters and hoses.
Advantages of Air Film Technology
Air Film Technology offers several advantages over conventional load-moving techniques.
- Exceptional Load Capacity
Systems are capable of handling weights ranging from 1 ton to more than 100 tons and can therefore be used in various sectors, such as electronics and aerospace.
- Minimal Effort
Since the air cushion eliminates friction, the operator can use only 50 pounds of force to move a 5,000-pound (2,268 kg) load.
- Cost-Effective Operation
Air film systems need no fuel or batteries, and costly hydraulics are not required, as they only need compressed air.
- Precision Movement
The micro-thin air cushion provides fine steps of loads, within the millimetre range. This is particularly vital in industries such as those producing heavy machinery or medical equipment.
- Space Efficiency
Air casters are low-profile (may be as thin as 1.5 in.) devices. They can squeeze under machines and move into narrow areas that forklifts are unable to penetrate.
- Safety and Cleanliness
Air film systems are free of sparks, vibrations, or mechanical wear since they do not have any wheels or bearings of any type.
- Scalability and Flexibility.
Adding modules or upgrading compressors are simple ways of increasing capacity for the user. Air film technology users have great flexibility, offering 360-degree lateral rotation.
Conclusion
Air Film Technology is not just industrial equipment; it is a solution that is revolutionizing the transportation of heavy loads. Since the early development of the technology in the 1950s in Britain, it has evolved to its current implementation in aerospace, manufacturing, and medical equipment management.
Air Film Technology is an ergonomic solution for large-scale industrial moving or heavy-duty modular kit extreme loading. It not only reduces labor but also enhances the safety, efficiency, and flexibility of operations, as it can move objects of up to 100 tons using compressed air.
To learn more about available systems, technical specifications, and starter kits, visit https://cargotrolley.com/ to explore an extensive selection of load-moving solutions powered by air.