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Engineered magnetic wheel assemblies for reliable adhesion on curved steel surfaces
FAIZEAL magnetic wheels are purpose-built traction and adhesion components for mobile robotic platforms that must stay attached to ferromagnetic structures under load. Each magnetic wheel assembly pairs high-energy NdFeB magnets with a precision-machined steel shell and an optional polyurethane-coated tread, delivering high adhesion force with true zero-slip contact on flat, curved, and weld-seamed steel surfaces. With two product families — cylindrical magnetic locomotion wheels (W Series) and curved magnetic wheel segments (R Series) — the platform covers payload classes from a few kilograms to heavy-duty inspection and cleaning crawlers. All products are available for OEM/ODM customization with full DFM support, so the wheel geometry, magnetization pattern, coating, and shaft interface are matched to your robot, not the other way around.
· High adhesion force from a compact package. W Series cylindrical magnetic wheels deliver up to 2940 N of holding force in a single Ø160 mm wheel; R Series magnetic wheel segments reach up to 4850 N per segment at zero air gap. Adhesion is measured against a 10 mm S235JR steel plate at room temperature (1 kg ≈ 10 N), so the published figures reflect real-world pull, not optimistic magnet-grade math.
· Zero-slip traction by design. The working face is a polyurethane-coated tread over a sealed magnet assembly. The polyurethane layer raises the coefficient of friction against wet, oily, or painted steel while the magnetic field does the load-carrying — the wheel grips without relying on wheel weight, which is what lets a light robot carry a heavy-duty payload on a vertical wall.
· NdFeB magnets with optional Halbach array. Standard assemblies use sintered NdFeB magnets (N35–N52, SH/UH/EH temperature grades). For weight-critical platforms, the Halbach array option concentrates flux toward the working face, raising air-gap flux density by 25–40% and improving the adhesion-to-weight ratio by roughly 2.5× compared with a conventional radial-magnet wheel of equal mass.
· Built for curved steel surfaces, not just flat plates. Both families are engineered around a defined air gap. The R Series segments are contoured to the pipe or tank radius and maintain rated adhesion through flange steps and weld seams within the specified gap. The W Series cylindrical wheels bridge curvature via compliant mounting and a wide urethane contact band.
· Sealed construction for harsh environments. Magnets are fully encapsulated in the steel shell — no exposed magnet surfaces to chip, corrode, or snag. Surface options include Ni-Cu-Ni plating (1000 h salt spray) and a polyurethane coated variant for abrasion and oil resistance, so the wheel survives hull cleaning, tank interiors, and outdoor steel structures.
· Magnet material: sintered NdFeB (N35–N52, SH/UH/EH grades); optional SmCo for elevated temperature.
· Shell / frame: low-carbon steel shell (W Series), 304/316L stainless steel frame (R Series).
· Surface: Ni-Cu-Ni triple plating (20–35 μm) or polyurethane coated tread.
· Working temperature: rated to 100°C standard; higher grades available.
· Encapsulation: fully sealed magnetic circuit, no exposed magnet.
The W Series is a complete cylindrical magnetic wheel family with H7 bored hubs and integrated keyways for direct shaft mounting. Nine standard sizes span Ø25 mm to Ø160 mm. Minimum order quantity is 4 pieces. FZW80 and larger offer a weight-reduced variant holding the same adhesion at lower mass.
Model |
OD D (mm) |
Bore d (mm) |
Width W (mm) |
Key b (mm) |
Key h (mm) |
Force (N) |
Temp (°C) |
Weight (kg) |
FZW25 |
25 |
8 |
16 |
3 |
8.6 |
55 |
100 |
0.054 |
FZW32 |
32 |
10 |
18 |
4 |
11.1 |
80 |
100 |
0.1 |
FZW40 |
40 |
12 |
20 |
4 |
13.1 |
120 |
100 |
0.2 |
FZW50 |
50 |
16 |
25 |
5 |
17.3 |
200 |
100 |
0.35 |
FZW63 |
63 |
20 |
32 |
6 |
21.7 |
330 |
100 |
0.7 |
FZW80 |
80 |
25 |
40 |
8 |
26.7 |
630 |
100 |
1.45 |
FZW100 |
100 |
30 |
50 |
8 |
31.7 |
900 |
100 |
2.8 |
FZW125 |
125 |
40 |
62 |
12 |
42.1 |
1520 |
100 |
5.35 |
FZW160 |
160 |
50 |
80 |
14 |
52.6 |
2940 |
100 |
11.4 |
Adhesion follows the inverse-square law — force drops as the square of the air gap. The published 0/3/5 mm figures let you size the wheel to the robot's actual ground clearance and predict holding force at the worst-case seam or coating thickness, instead of discovering it in the field. Test condition: room temperature, S235JR steel plate, 10 mm thickness (1 kg ≈ 10 N).
· Wall-climbing robot. Facade inspection, ship hull cleaning, and tower maintenance robots use the W Series as the primary adhesion and drive element, holding the platform on vertical and overhead steel while carrying sensors, tools, or spray systems.
· Pipe inspection robot. The R Series contoured segments wrap pipes and elbows, giving a pipe inspection robot continuous magnetic contact through bends, weld rings, and diameter changes without losing adhesion.
· Tank crawler. Internal and external storage-tank crawlers use magnetic wheel assemblies to traverse curved and coated steel under a heavy-duty payload of gauges, scanners, and cleaning heads, with the polyurethane coated option protecting linings from abrasion.
· Hull cleaning. Underwater and topside hull-cleaning platforms rely on sealed, corrosion-resistant magnetic locomotion wheels that hold through marine growth and coatings while the brush or cavitation head does the work.
· Curved steel surface inspection and maintenance. Any mobile platform that must remain attached to a non-flat ferromagnetic structure — pressure vessels, wind-tower sections, bridge girders, rail and rolling stock — is a direct fit for the family.
· Geometry: diameter, width, bore, keyway, and arc radius matched to your drivetrain and structure.
· Magnetization: radial or Halbach array, pole count and pole-arc coefficient tuned for your gap and torque.
· Coating: polyurethane coated (PU/NBR/HNBR/EPDM by media), Ni-Cu-Ni, or bare sealed shell.
· Shaft interface: H7 bore, keyway, through-bore, or custom hub.
· Compliance: compliant arm and preload options for flange and seam transition.
DFM support is part of the engagement, not a paid extra. Engineering reviews your robot's mass, center of gravity, speed, and ground clearance up front, then recommends wheel size, count, and air-gap budget so the heavy-duty payload requirement is met with margin rather than guesswork. Prototypes are typically available within weeks; production scales to volume with the same tooling and inspection.
FAIZEAL (Ningbo Fengzheng Magnetic Application Technology Co., Ltd.) has specialized in custom magnetic assemblies since 2017 and supplies magnetic components to robotics, new-energy, and industrial customers across more than 30 countries. Magnetic wheels, Halbach rotors, and magnetic couplings are core products, not sidelines — the magnetization, encapsulation, and inspection are done in-house, and every wheel ships with flux-mapping and dimensional verification.
If you are specifying a magnetic wheel assembly for a wall-climbing robot, pipe inspection robot, tank crawler, or hull-cleaning platform, send your robot mass, mounting surface, and gap budget. We will return an adhesion-to-weight analysis, a recommended magnetic locomotion wheel or segment configuration, and a DFM-driven quote — standard catalog or fully customized. Contact FAIZEAL for the complete W/R series parameter sheet and OEM/ODM project support.
FAIZEAL can provide technical support for magnetic wheel selection, Halbach array design, and custom magnetic wheel assembly development.
