BIZOMAT MAKEOS · Mechanics
Cart Push Force Check (Rolling Resistance, Slope, Starting Force, Wheel Load)
How hard will it be to start and keep a loaded trolley moving on this floor and slope, and are the wheels rated for the load?
Check of a manually pushed cart, trolley or dolly: the rolling resistance from the load, wheel radius and coefficient of rolling resistance (as the rolling resistance tool), the force to push the load up the slope (as the inclined plane tool, with rolling instead of sliding), the force to accelerate it from rest, the starting and keep-moving push forces, and the load on each wheel with the number sharing the load on an uneven floor, against your push force limits and the wheel rating.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Loaded mass | kg | Mass of the cart and its load. |
| Number of wheels | wheels | Number of wheels or castors. |
| Wheels sharing the load on an uneven floor | wheels | Wheels that carry the load when the floor is uneven (often one fewer than fitted for four wheels). |
| Wheel diameter | mm | Wheel diameter. |
| Coefficient of rolling resistance | mm | Coefficient of rolling resistance (lever arm, mm) for the wheel tread and floor; soft treads and soft floors are higher. |
| Slope | ° | Slope of the floor or ramp. |
| Starting acceleration | m/s² | Acceleration from rest when starting the push. |
| Limits | ||
| Largest starting push | N | Largest force a person should apply to start the cart (from your manual handling guidance). |
| Largest keep-moving push | N | Largest force to keep it moving. |
| Rating of each wheel | N | Load rating of each wheel or castor. |
What each input means
Open an input to see what it is, its units, the worked example and the common mistakes, with a small diagram.
What this means: Loaded mass
- What it is
- The total mass being pushed: the cart or trolley itself plus everything loaded on it.
- Units and format
- Enter a number in kg: kilograms. The form accepts 0.000001 kg to 1000000 kg. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 300 kg as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Every push force and the wheel load rise in proportion to it.
- Get it right
- Include the cart’s own mass, not just the load.
What this means: Number of wheels
- What it is
- The number of wheels or castors fitted to the cart. It is used to check that the wheels sharing the load do not exceed those fitted.
- Units and format
- Enter a number in wheels: wheels. The form accepts 2 wheels to 32 wheels. Use a whole number. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 4 wheels as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Get it right
- Count every wheel or castor touching the floor when it is flat.
What this means: Wheels sharing the load on an uneven floor
- What it is
- Units and format
- Enter a number in wheels: wheels. The form accepts 1 wheels to 32 wheels. Use a whole number. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 3 wheels as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Fewer sharing wheels raise the load on each wheel.
- Get it right
- A rigid four-wheel cart often rocks on three wheels; it cannot exceed the wheels fitted.
What this means: Wheel diameter
- What it is
- The outside diameter of the wheels or castors, including the tread.
- Units and format
- Enter a number in mm: millimetres. The form accepts 0.000001 mm to 5000 mm. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 150 mm as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Rolling resistance falls in proportion as wheel diameter increases.
- Get it right
- Enter the diameter, not the radius: the tool halves it.
What this means: Coefficient of rolling resistance
- What it is
- The coefficient of rolling resistance expressed as a lever arm: how far ahead of the wheel centre the floor reaction acts because tread and floor deform.
- Units and format
- Enter a number in mm: millimetres. The form accepts 0.000001 mm to 100 mm. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 0.5 mm as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Rolling resistance rises in proportion to it.
- Get it right
- It is a length in mm, not a dimensionless ratio; take it from the castor maker for your tread and floor.
What this means: Slope
- What it is
- The angle of the floor or ramp the cart is pushed up, measured from the horizontal.
- Units and format
- Enter a number in °: degrees of angle. The form accepts 0° to 30°. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 2° as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- The force to push up the slope rises with the sine of the angle.
- Get it right
- Enter degrees, not a percentage grade; a gradient of 1 in 20 is about 2.9°.
What this means: Starting acceleration
- What it is
- The acceleration given to the cart when starting it from rest, which adds a force of mass times acceleration to the starting push.
- Units and format
- Enter a number in m/s²: metres per second squared. The form accepts 0 m/s² to 10 m/s². Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 0.3 m/s² as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- The starting push rises in proportion to it.
- Get it right
- Base it on how quickly the cart needs to reach walking speed; slower starts need less force.
Limits
What this means: Largest starting push
- What it is
- The largest force you accept for a person to start the cart moving, compared with the starting push.
- Units and format
- Enter a number in N: newtons. The form accepts 0.000001 N to 1000000 N. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 220 N as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Get it right
- Take it from your manual handling guidance or a competent ergonomics assessment; the tool does not suggest one.
What this means: Largest keep-moving push
- What it is
- The largest force you accept for a person to keep the cart moving at steady speed, compared with the keep-moving push.
- Units and format
- Enter a number in N: newtons. The form accepts 0.000001 N to 1000000 N. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 150 N as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Get it right
- Take it from your manual handling guidance or a competent ergonomics assessment.
What this means: Rating of each wheel
- What it is
- The load rating of one wheel or castor from its maker, compared with the load on each sharing wheel.
- Units and format
- Enter a number in N: newtons. The form accepts 0.000001 N to 100000000 N. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 1000 N as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Get it right
- Enter it in newtons: a rating in kg multiplied by 9.81 gives N.
Method and formulas
- Rolling resistance F = W cos θ × f ÷ r (as the rolling resistance tool).
- Slope force = W sin θ (as the inclined plane tool with no sliding friction); acceleration force = m a.
- Start = rolling + slope + acceleration; keep moving = rolling + slope; wheel load = W ÷ wheels sharing.
- Example: 212.28 N to start and 122.28 N to keep moving; each wheel carries 980.66 N.
Limitations
- Swivel castor alignment and bearing friction add to the starting force.
- Push forces only; pulling, turning and stopping on slopes need separate checks.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Check a trolley design against push force limits
- Choose wheel size and type for a floor
- See how a ramp changes the push force
Who it is for
- Design engineers
- Safety advisers
- Materials handling engineers
What you get
- Rolling, slope and acceleration forces
- Starting and keep-moving push
- Wheel load
Interpreting the result
- Doubling the wheel diameter halves the rolling resistance; on a ramp the slope force soon dominates.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 165–171. Topic reference; no source tables or recommended settings are reproduced.
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Open the Cart Push Force Check (Rolling Resistance, Slope, Starting Force, Wheel Load) calculator