Two road moves that shaped CargoRide

Both jobs were sized, built and reported by Adoni Tech in 2025–26. Customer names are withheld; the engineering is as delivered.

Case A · Flatbed, compression

5 t process payload, road move to plant, North India

Cargo

5 000 kg skid-mounted process equipment

Arrangement

Below cargo, compression, isolators aligned with the direction of travel

Isolators

Ø28 mm rope, 8-loop heavy isolators (AWRI 286 class)

What we learned

The braking check showed the cargo would travel fore-aft beyond comfortable isolator stroke under hard braking. Elastomer end-stops were added, four at the front and four at the rear, set clear of normal running.

Case B · Outside container, 45° at ISO corners

12.5 t defence electronics enclosure, 40 ft trailer

Cargo

12 500 kg enclosure, 6060 × 3330 × 2600 mm, CG 1100 mm, four ISO-corner supports

Requirement

20 g / 11 ms road shock, 3 g limit on the equipment, 24 Hz enclosure mode

Selection

12 × AWRI 318-40 at 45°, three per corner

Result

2.7 g transmitted, fn 7.24 Hz (ratio 3.3 to the 24 Hz mode, 86 % attenuation), 67 of 137 mm travel used at the heaviest corner

What we learned

With CG 1210 mm on a 2259 mm corner track the enclosure tips at 0.86 g lateral. A 1.5 g side load would lift the windward rail, so the twist-locks become structural members. Tipping is now checked on every CargoRide selection.

Real isolators, real tests

Every CargoRide isolator is wound, clamped and tested in our own works. These are production parts, photographed on the shop floor and in the test bay.

Pick the load line first

The same isolator has three load lines, each with its own rating, stiffness and stroke. The catalogue gives all three for every AWRI model (rows C, R and S).

0° Compression row C

Gravity squeezes the loops. Highest load per isolator and the stiffest vertical rate, so the fewest pieces. Horizontally it is soft: fore-aft and sideways run on the shear/roll rate.

• Low, wide cargo; CG height under half the narrow base
• Flatbed skids, container floors
• Always fit fore-aft end-stops

45° Compression / roll row R

Isolators lean at 45°, in pairs leaning opposite ways. Vertical and lateral stiffness become nearly equal, so the cargo rides as one block and rocks far less.

• Tall cargo, high CG, cabinets and shelters
• ISO-corner container kits
• The longest stroke of the three rows

90° Shear / roll row S

Base on a vertical face, gravity across the loops. Lowest rating, softest rate. Used to hang cargo from its side, and as top stabilisers that stop a tall load from swaying.

• Side-mounted cabinets and racks
• Top stabilisers to container walls
• Rated at about a quarter of row C

Five arrangements, one method

C

Below cargo, on the flatbed

The cargo's own skid sits on an upper frame carried by isolators in compression. A lower rail set bolts or twist-locks to the deck. Fore-aft end-stops and lateral snubbers are welded to the lower set with a set gap. The arrangement used for Case A.

Use for: skids, gensets, transformers, machine tools, process modules up to 12 t.

V

45° V-pairs, below tall cargo

Same frame set, isolators at 45° in opposed pairs. Lateral rate equals vertical rate, so a tall load does not rock on a soft base.

Use when CG height exceeds half the narrow base.

I

Inside the container

An isolated skid on the container floor, plus shear/roll stabilisers from the top of the cargo to the side walls. The container stays a standard box on a standard trailer.

Use for: rental moves, multimodal rail-road, shared trailers.

Let the isolator float, then stop it

A wire rope isolator is soft sideways on purpose. Under 0.8 g braking a 12 t skid on ten AWRI 318-40 in compression moves forward 18.3 mm, then swings back when the brakes come off. That to-and-fro is harmless within the isolator's travel. It becomes a problem on repeated hard braking, on a downhill ghat, or in a collision.

End-stops are rigid brackets with an elastomer face, welded to the lower frame and set with a clear gap to the cargo frame. In normal running they never touch. When travel exceeds the gap they pick up the load, so the isolator is never driven past its stroke.

The gap rule

gap = 1.25 × δ_{0.5 g}   with   δ_a = a · M · g / (N · K_s,h)

δ_{0.5 g} is the deflection under ordinary firm braking. K_s,h is the isolator's large-amplitude rate in the horizontal load line (row S for compression mounts, row R for 45° mounts).

Stop design load

F_stop = 1.0 · M · g − N · K_s,h · gap

The share of a 1.0 g emergency stop the isolators cannot carry at the gap. Split over the stops on one face, then ×1.5 for the stop rating.

End-stop on a compression mount: deck-welded gusseted bracket, elastomer face, running gap to the orange cargo frame.

Four sizes, two arrangements, off the shelf

Each package is a complete kit: isolators, lower and upper frame rails, end-stops, snubbers, fasteners, installation drawing and a selection report. Sized for the reference cargo below and valid for R1 to R3 roads.

Reference cargo for each size: CR-04 3.0 × 2.0 m footprint, CG 1.0 m; CR-06 4.0 × 2.2 m, CG 1.1 m; CR-08 5.0 × 2.3 m, CG 1.2 m; CR-12 6.0 × 2.4 m, CG 1.2 m (CG above isolator plane). Worst-corner load includes a 15 % CG-offset allowance, shown as a share of the isolator's rated static load. Transmitted shock on the cargo, damping 0.15. If your cargo differs, the selection tool resizes the package in a minute.

The parts behind every package

AWRI heavy isolators used in CargoRide (rated static load per isolator, kN)

Family	Rope, mm	Models	Row C	Row R	Row S	Stroke R, mm
AWRI 95	Ø9.5	14	0.4 – 2.1	0.4 – 1.7	0.2 – 1.3	48 – 95
AWRI 127	Ø12.7	16	1.3 – 5.1	0.9 – 3.6	0.3 – 4.1	44 – 145
AWRI 159	Ø15.9	7	3.9 – 9.0	2.8 – 6.4	1.4 – 4.9	45 – 101
AWRI 222	Ø22.2	6	5.2 – 17.2	3.0 – 12.2	1.1 – 8.6	72 – 178
AWRI 286	Ø28.6	3	17.9 – 23.6	11.1 – 16.8	3.8 – 8.8	96 – 169
AWRI 318	Ø31.8	2	24.6 – 30.3	17.4 – 21.4	6.5 – 11.7	96 – 137

Full data for all 114 AWRI and ACWRI models, with competitor cross-reference, in the AWRI selector at awri-selector.netlify.app.

AWRI heavy isolator as supplied: stainless rope, black-finished retainer bars, stainless fasteners. All-metal, no ageing, works from −50 to +120 °C.

One code describes the whole package

Example: CR-08-V-R3-EF — 8 t cargo on 45° V-pairs, rural/ghat roads, elastomer end-stops, frames supplied.

7.5 t radar shelter to a hill site

1. Arrangement

   h_CG = 1.35 m > B/2 = 1.15 m, so the cargo is tall for its base. Rigid tipping threshold a_tip = 1.15 / 1.35 = 0.85 g, above the 0.7 g check but not by much. Choose V, 45° pairs.

2. Worst-corner load

   f = (1 + e_L/a)(1 + e_T/b) = (1 + 0.15/2.3)(1 + 0.08/1.15) = 1.139. Weight W = 7 500 × 9.81 = 73.6 kN. Try N = 8: nominal 9.20 kN, worst 10.48 kN per isolator.

3. Isolator

   AWRI 318-40, row R: 17.37 kN rated. Worst-corner utilisation 10.48 / 17.37 = 60 %, under the 80 % limit.

4. Vibration

   f_n = (1/2π)·√(N·K_v/M) = (1/2π)·√(8 × 2 158 000 / 7 500) = 7.64 Hz, inside 5–10 Hz. At the 30 Hz shelter mode, T = 0.107: 89 % attenuation.

5. Shock

   On K_s: f_s = (1/2π)·√(8 × 529 000 / 7 500) = 3.78 Hz. Half-sine 8 g / 15 ms solved as a damped single-degree system (ζ 0.15): 1.53 g on the cargo, under 3 g. Deflection 25 mm average, 29 mm at the worst corner, of 137.2 mm.

6. Braking and end-stops

   Row R horizontal K_s = 529 N/mm. δ_{0.8 g} = 0.8 × 73 575 / (8 × 529) = 13.9 mm. δ_{0.5 g} = 8.7 mm, gap = 1.25 × 8.7 = 10.9 mm. F_stop = 73.6 − 8 × 0.529 × 10.9 = 27.6 kN on two stops, ×1.5 → 21 kN each: AES-40.

7. Rocking

   Moment at 0.7 g: 0.7 × 73.6 × 1.35 = 69.5 kNm. Roll stiffness N·K_s·(B/2)² = 8 × 529 000 × 1.15² = 5.60 MNm/rad. Roll = 0.71°, 34 mm sway at the roof. Light-side isolators stay in compression (1.6 kN each).

8. Why not compression?

   8 × AWRI 286-60 in compression passes the vertical checks (59 %, 7.3 Hz, 1.66 g) but its horizontal frequency is 3.2 Hz, inside the truck's body-roll band, and braking travel is 24 mm. A tall shelter would sway. Rejected.

Send us these, we send a selection

Works: Suvarna Laghu Udyog, Shed No 39, Addl. MIDC Kodoli, Satara 415004 · Branch office: Pune

sales@adonitech.co.in · +91 93074 46007 · www.wireropeisolater.com · www.adonitech.co.in · GSTIN 27AHAPA3555B1Z1

Wire rope isolators · Industrial shock absorbers · Crane buffers · Rubber anti-vibration mounts · Pneumatic rodless cylinders · Linear slides