Couplings & Connections

2. The Bolt-on

Another type of coupling, and often our preference at MasterMover for heavier loads requiring added security, are couplings that are securely bolted onto your carts. These typically work by using a male (mounted on the electric tugger) that interlocks with a female (installed on your cart) to create a strong connection.

On our machines, this coupling configuration is essential to achieve the process of ‘weight transfer’, a clever way of transferring some of the load’s weight, through the coupling system down through the machine’s drive wheel – allowing it to gain traction, move and brake the load.

This type of coupling enables you to have an unbreakable connection to the load, move heavy weights, and provide you with maximum security and control of the load. However, the nature of this means a female coupling needs to be bolted or installed to each cart or platform you want to move. It’s important to consider the feasibility of installing multiple couplings on high volumes of carts or platforms and to weigh this up against the standardization it provides you with.

Our CombiCoupling system delivers powerful performance and guarantees complete control and maximum maneuverability.

Tip: Electric tugger suppliers should happily provide you with 3D CAD models of their coupling designs to enable you to review this alongside your existing equipment and review a suitable mounting point.

4. The Custom Coupling

Where a standard solution isn’t suitable, an experienced supplier will work with you to assess if a customized coupling can be designed. Situations where this often arises are where you may have a high quantity of carts that can’t be modified, no obvious connection point, or where there are space restraints on your cart.

A custom coupling design is often seen as an attractive option in these situations, or when the task of modifying a range of carts to achieve standardization seems too difficult.

However, this approach should be viewed with caution and carefully considered. As with anything custom, custom coupling designs typically come at an increased cost and lead time and there is nearly always a trade-off in creating a multifunctional coupling design. Cost, ease of use, and performance are all areas where a custom design might demand compromise.

The other risk with creating a unique custom coupling is that it hasn’t been tried and tested. Custom couplings cost time and money and so, if possible, it’s better to push for a standardized cart design. However, for many manufacturers with specialist set-ups, custom couplings are essential to facilitate connection where unique processes or requirements dictate that modifying carts isn’t feasible.

Where a custom coupling is required, it is important to make sure you’re working with a supplier who’s up to the task. At MasterMover, we have a Customer Engineering team dedicated to creating custom solutions to complex connection requirements. With 25 years of industry knowledge, we’ve built a proven track record in designing customized couplings for customers across the globe.

Tip: If you’ve assessed that a custom coupling is required, it’s important that when working with a supplier to design a custom connection that full technical data is provided and accurate to make sure any proposed coupling is designed correctly.