What a flanged track roller is
A flanged track roller combines three components in one unit: the actual flanged track wheel, the bearing (usually ball bearings, in the heavy-duty sector also precision ball bearings or roller bearings) and a solid block housing made of welded steel plate or cast steel. The complete roller is screwed directly to the structure – on the gate, on the chassis, on the machine or on a supporting structure – via the mounting plate on the block housing. A separate axle shaft, shaft machining or bearing seat construction is not required.
Thus, the flanged track roller is the ready-to-install alternative to the loose flanged track wheel. It is chosen when installation time needs to be short, when constructive shaft adaptation is not possible, or when the wheel is to run in a position where there is no continuous shaft.
Standard or Heavy-Duty Flanged Track Roller?
The standard flanged track roller is designed for load ranges up to approx. 1,500 kg per roller. It is used in sliding gates, shifting units, light overhead conveyors, special machines and furniture applications. Block housing made of welded steel plate construction, 6000 series deep groove ball bearings, black painted or galvanized.
The heavy-duty flanged track roller is dimensioned for loads from 2,000 kg to over 10,000 kg per roller. It is used in crane systems, gantry cranes, trolleys, heavy-duty sliding platforms, heavy gates and industrial material flow systems. Reinforced cast steel or thick-walled welded housing, precision ball bearings or cylindrical roller bearings, robust mounting plate with heavy-duty drilling pattern.
For both variants: the stated load capacity refers to static to intermittent loading on a smooth, even running surface. For higher speeds, frequent load changes or shock loads, the load capacity must be reduced accordingly.
Typical Applications
Flanged track rollers are used wherever a track-guided wheel is needed at a fixed bolted position:
- Sliding gates, sliding walls and industrial doors with running rails
- Sliding platforms, shifting units and wall suspensions
- Overhead conveyors, material flow systems and profile rail constructions
- Trolleys, gantry cranes and crane systems (heavy-duty)
- Heavy-duty sliding walls and industrial partitioning systems
- Special machines with fixed track guidance
- Track-guiding applications on support profiles (IPE, IPN, UPE, UPN)
- Repair and conversion applications when the original shaft no longer fits
Structure and Design
Block Housing: Welded steel plate construction for standard versions, cast steel or reinforced welded construction for heavy-duty variants. Surface black painted or galvanized, also available in special colors or with stainless steel block housing on request.
Wheel: single flange, turned from the chosen material. Running diameter and flange geometry are matched to the respective rail or profile type.
Standard Bearing: 6000 series deep groove ball bearings, double-sealed and permanently lubricated. Low maintenance for most applications.
Heavy-Duty Bearing: Precision ball bearings (two side-by-side) or cylindrical roller bearings for high radial loads and continuous use under heavy load.
Fastening: Mounting plate with standard drilling pattern on top or side of the housing. Special drilling patterns, longer mounting brackets, adjustable mounting plates for height compensation or heavy-duty mounting plates with a larger drilling pattern on request.
Material Variants for the Tread
Steel Wheel – the robust standard choice for medium to heavy loads on rails and support profiles. High load capacity, long service life, suitable for indoor and protected outdoor areas.
Polyamide Wheel (PA6 G) – the light and low-noise variant for applications with low to medium load ranges. Corrosion-free, chemical-resistant, ideal for sliding gates, furniture and lightweight constructions.
Polyurethane Tread on Steel Core – the floor-friendly variant for applications where the floor or sub-surface should not be damaged. Low-noise running, abrasion-resistant, suitable for high-quality industrial floors and indoor areas.
Vulkollan® Tread on Steel Core – the premium choice for heavy-duty flanged track rollers in 24/7 continuous operation, in crane systems, high-bay warehouses and heavily loaded material flow systems. Highest dynamic load capacity, no flat spots after standing times, extremely abrasion-resistant.
Stainless Steel Variant (1.4301 V2A) – for damp, corrosive or hygienically critical environments such as food, pharmaceuticals and outdoor use. Block housing and wheel made of stainless steel. Custom-made; price and delivery time on request.
Load Capacity and Dimensioning
For gates and sliding platforms, two flanged track rollers are usually used per element – so each roller carries half of the total weight. With four flanged track rollers, the load distribution is more favorable, but never completely even: individual rollers can briefly take on the full load share on uneven surfaces. For dimensioning, we recommend a safety factor of 1.5 to 2 on the mathematically required load capacity.
For heavy-duty applications such as crane systems, the relevant standards for design (DIN 15018, DIN 15070, FEM rules) also apply. We are happy to assist with material and size selection for your specific application.
Standard Program and Special Production
Our standard program includes flanged track rollers with running diameters from 50 to 200 mm and heavy-duty flanged track rollers from 150 to 400 mm in the common material variants. Special diameters, special mounting plates, deviating flange geometries or flanged track rollers for special rail profiles (IPE, IPN, UPE, UPN, DIN 536 crane rail) are manufactured on request.
Double flanged track rollers with two parallel running flanged track wheels for even higher load capacity, flanged track rollers with height-adjustable mounting plate or with additional torque support are also available as special designs.
Distinction from Loose Flanged Track Wheel
If the wheel is to be installed in an existing structure with its own shaft, you will find our loose flanged track wheels with ball bearings or keyway in the respective material categories (steel S355, stainless steel V2A, polyamide, with polyurethane or Vulkollan® tread). The flanged track roller is the convenient solution if no separate shaft construction is to be built or cannot be built.
