What Is An Air Bearing?

An air bearing is a device, usually made from a rubber-type fabric, that is designed to
inflate with compressed air and forms a floating action above the floor surface it is sitting
on.

Incorporated into an air caster load module, the air bearing is then used, with others in a
series of three or more, to simultaneously float heavy loads away from the floor surface on
a thin film of air thus allowing the loads to be floated - similar to a hovercraft - to a new
destination.

How Do Air Bearings Work?

Air bearings are designed to lift loads away from the floor surface and float them off to their
destination on a thin film of air. Each individual air bearing is housed in a load module which
contains an air flow control valve to regulate the operation of that air bearing.

When compressed air is introduced into the air bearing, the bearing initially inflates to form
a seal between the bearing and the floor surface. As the air bearing is further pressurized it
is forced to expel compressed air from the exhaust holes in the air bearing diaphragm. The
force of this expelled air against the floor surface causes the air bearing and load module to
lift off the floor on a thin film of air. The load should now be in flotation mode and ready for
action.

Do Air Bearings Work Individually?

No. Air bearings need to be coupled with other air bearings, in sets of three or more, to
form a system that can handle an appropriate load. An individual air bearing is not able to
balance a load on its own - it will tip easily -  nor is it capable of being adjusted to
accommodate variations in load weight and irregular shape. The strength of air bearing
lifting power becomes apparent when they are grouped together and their collective lifting
abilities are combined to offer some formidable lifting capacities.

When air bearings are grouped together to form an air bearing system, they then offer
some real lifting power. The beauty of using air bearings in groups of three or more is that
they can be individually adjusted to suit the properties of the load they are carrying.

Where Does The Air Plug Into The Air Bearing?

Compressed air is introduced into an air bearing system in one of two ways:

1. If the air bearing is part of a manually operated system, (no remote control unit)
then each load module will contain an air flow control valve on one of its edges. This
air flow control valve can be used to control an individual air bearing by increasing or
decreasing the amount of air being applied to the bearing.

2. If the air bearing is being used as part of a remote controlled system, the load
module will have an air inlet port on one of its edges. This port accepts an air supply
hose, fitted with quick disconnects, which runs to an air outlet port from the remote
control unit. Air flow control to the bearing is controlled from the remote control unit.
Where Does the Shop Compressed Air Supply Connect?

Air bearing systems are powered by regular compressed air that runs around most industrial
facilities.

All of our systems and air other powered products have an air inlet port, or flow control
manifold, to connect the shop compressed air supply to.

In the case of air bearing systems using, say, a four or six station setup, the shop
compressed air supply would connect directly to an air flow control manifold. An on/off ball
valve on the manifold then controls the air flow to the air flow control valves on each load
module. Individual air bearing control is then applied at the air flow control valves.

In the case of air bearing systems that are controlled via remote control, the shop
compressed air supply is connected directly to the inlet port of the remote control unit. The
remote control unit then controls the air flow to each individual load module and air bearing.

What Minimum Air Pressure Should My Shop Supply Be?

On a standard air bearing system using regular A-type air bearings the required minimum
air pressure from the shop supply should be 70 psi.

On air bearing systems using B-type air bearings the minimum required air pressure from
the shop supply should be 70 psi.

The volume of air required will differ depending on the floor surface, the weight of the load,
and the type of bearing being used. All air requirements will be explained to you at the time
of order.

Are Air Bearings Easy To Replace?

Absolutely. At Hovair Systems we manufacture all our products with the customer in mind.
This means that most individual components are easy to locate and replace if necessary.

A-type air bearings are fitted to their load modules by a single hex-head bolt through the
load pad and into the load module.

B-type air bearings are usually mounted on an aluminum back plate which is fitted to the
load module via a mounting bolt on each corner. There is also a center fitting bolt through
the load pad.

VL-type air bearings are not replaceable as they are incorporated directly into their stainless
steel modules. In the event that an air bearing needs to be replaced, simply replace the
complete module.

Air bearings are also very easy to replace when they are incorporated into products such as
aluminum transporters, air pallets, air beams, lifting jacks and vehicle turntables etc.

Every product that leaves our factory has an operator's manual that covers the air bearing
replacement process for that product.
What Is A Load Module Or Air Caster?

A load module or air caster is a machined assembly - either lightweight aluminum or steel -
that houses an air bearing.

Load modules - also known as air casters - are available for each size of air bearing.

Load modules are fitted with inlet ports, or air flow control valves, and contain air chambers
that allow air to flow from the inlet to the air bearing to cause pressurization and eventual
flotation to take place.

Shown to the right is a typical square aluminum air caster module. The yellow part is the
actual air caster load module and the black inner section is the air bearing assembly

How Is A Load Module Or Air Caster Used?

Load modules - also known as air casters - are used primarily to house individual air
bearings and their load pads to make them ready for operation. An air bearing cannot work
on its own. It needs a load module to cause it to receive compressed air, pressurize, and
float away from the floor surface.

Load modules are used

in multiples of three and more and are flexible in that they can usually form a footprint of
the load to be moved, and have the load applied directly on the modules and then floated
off to their destination.

One of the most effective uses of Hovair Systems load modules is in machinery movement.
Sliding three or four modules underneath a machine is a breeze. However, some clients
prefer to fix the load modules directly to their machines permanently. Then, when the
machine needs to be moved, just plug in your shop air, and bingo!... it's on its way. It really
is that simple.

Shown to the right is a typical air caster module footprint layout showing a four-module
system complete with air supply hose and tee-piece fittings back to the shop air supply.

Air Bearing Remote Control Systems

All of our air bearing and load module systems can be controlled via an optional remote
control unit. Remote control units make it very easy to adjust individual air bearings -
increase/decrease air pressure - from one central location without the need to go to each
module in turn to make adjustments.

Remote control units have a main shop compressed air inlet and corresponding air pressure
gauge, and individual inlets and air pressure gauges for each load module in your system -
usually four or six.

Shown to the right is a typical square aluminum air bearing kit supplied with RC remote
control unit, hand-held pendant and all necessary air supply hoses.

Please note: Remote controls are an optional extra -  except on the Low Profile B-type Air
Bearing Kit system.

What's The Deal With Air Bearing Kits?

Very often we find that first time customers prefer to buy their air bearing system in kit
form with everything included. This has proved so popular an option that we now quote four
and six station kits as standard product items.

What does an air bearing kit consist of?

Air bearing kits are available in either square aluminum or round steel format. Whichever kit
you choose, it will be supplied complete with modules and pre-installed air bearings, valves,
air supply hose, tee-pieces, ball valves, and virtually everything else that is needed for your
system to work right out of the box.

First time setup is a breeze and you'll be moving loads in no time at all. All air bearing kits
come complete with easy to understand operator manual, plus you will always have Hovair's
free telephone and email support.

Do I have to use all the load modules in the kit?

No, not at all. You will need a minimum of three load
modules to produce a balanced and even footprint, and
if that is enough to move your load smoothly, then you
can put the others away for a while.

Having, say, a six station air bearing kit, however, does

offer greater flexibility when moving loads of uneven
weight distribution, or irregular shape. Perhaps you
have a load that is 10 tons at one end and only 3 tons
at the other. Naturally the ten ton end is going to need
more support than the three ton end. So, what to do?
Put four modules around the heavy end and two around the light end. Adjust the modules
appropriately and move the load smoothly and safely. Now THAT is flexibility!

Shown above right is a typical round steel air bearing kit as supplied with all tee-piece and
valve hardware, air supply hoses - without a remote control system.

What Sort Of Floor Surface Is Required?

For a smooth, trouble-free operation of your air bearing kit, or system, the floor surface
should be level, smooth and non-porous - preferably concrete. The best floor surface will
have no cracks, holes or indentations. Minor cracks and small holes can be easily filled with
an epoxy resin type material. See floor surface specifications.

In some cases it is permissible to lay sheets of aluminum-type sheeting to act as a pathway

for the load moving exercise. As long as the base surface is reasonable flat and level this
can work fine. Talk to one of our support staff for more info on this method.

Click the following link for a PDF containing more information.

Air bearing floor specifications.

What If I Don't Want A Remote Control System?

No problem, you don't have to. All our air bearing systems are available with or without
remote control.

Not all applications require their use either. Sometimes it is just a matter of convenience.

Not using a remote control permits you to control each individual load module and air
bearing manually by way of air flow control valves.
Shown to the right is a typical round steel air bearing kit as supplied without a remote
control system.

Different Types of Air Bearing

There are two types of air bearing to choose from - depending on the type of load you are
going to be moving. Loads generally fall into two categories: those that need just to be
floated away from the floor's surface and laterally moved across the floor, and those that
need to be vertically lifted away from their base before moving laterally across the floor.

Here are the main options to choose from:

A-type Air Bearings:

A-type air bearings cause their loads to lift away from the floor surface just enough to allow
them to be floated off to the destination. A-type air bearings when use in series of four or
more are capable of lifting and moving loads of up to 100 tons and beyond.

B-type Air Bearings:

B-type air bearings are a high-lift bearing which, when energized, cause the load to lift
vertically away from the floor surface as much as 3 inches, depending on the type of
bearing being used. These bearings are used when vertical lift is required before floating the
load away. Such loads could be dropped on low level custom-pallets or racking. B-type air
bearings when use in series of four or more are capable of lifting and moving loads of up to
100 tons and beyond.