1. Project Background

A large automotive manufacturing plant required an indoor rail cart system to transport heavy components between welding, painting, and assembly workshops.
The rail carts operate inside enclosed factory buildings, where noise control, floor protection, and smooth movement were critical requirements.

Traditional steel rail wheels previously used caused:

• Excessive rolling noise

• Vibration affecting sensitive equipment

• Increased wear on rails and supporting structures

The customer was seeking an alternative wheel solution that could operate on light rail tracks while improving working conditions.

2. Application Challenges

The project presented several technical challenges:

• Continuous operation in high-frequency daily shifts

• Medium to heavy load per cart

• Strict noise limits inside production halls

• Need to reduce maintenance on rails and wheels

• Limited installation space, requiring compact wheel dimensions

Steel wheels met the load requirement but failed to meet noise and vibration control expectations.

3. Kingrail Solution

Kingrail recommended a customized Polyurethane Railroad Wheel solution designed specifically for indoor rail cart applications.

Key solution features:

• High-performance PU tread bonded to a steel core

• Optimized wheel profile to match the existing rail system

• Medium-hardness polyurethane to balance load capacity and vibration absorption

• Precision bearings for smooth low-speed operation

Kingrail worked closely with the customer to confirm:

• Wheel diameter and tread width

• Rail contact surface design

• Load per wheel and operating speed

4. Product Performance in Operation

After installation, the Kingrail polyurethane railroad wheels demonstrated excellent performance:

• Rolling noise reduced by over 40% compared to steel wheels

• Significantly lower vibration transmitted to the cart frame

• Improved traction and stability during start/stop operations

• Reduced wear on rail surfaces

• Minimal maintenance required after long-term use

Operators reported a noticeably quieter and smoother transport process, especially in enclosed workshops.

5. Customer Value & Results

By switching to Kingrail polyurethane railroad wheels, the customer achieved:

• Improved working environment and operator comfort

• Extended service life of both wheels and rails

• Lower maintenance and downtime costs

• Stable, reliable performance in continuous production cycles

Kingrail’s polyurethane rail wheel solution proved to be a cost-effective and technically suitable alternative to steel wheels for indoor rail cart systems.