Is A Chassis Load Capacity of 100kg Sufficient?

In our communications with multiple end customers, we repeatedly encounter the same question: “Your chassis has a rated load capacity of 100kg, but what is the actual weight it can reliably transport?” This seemingly simple question reveals a widespread misconception and technical blind spot in current chassis selection practices. As a supplier with years of deep expertise in robotic chassis, we've participated in over 300 chassis deployment projects—from e-commerce warehouses to automotive plants, from ambient storage to cold chain facilities. Load capacity isn't a single parameter; it's a complex system engineering effort hidden in the details.

Now, let's dissect the two most overlooked critical issues in chassis selection for 2025 from a chassis designer's perspective and share our proven engineering experience validated in real projects.

1. “Static Load” does not represent the chassis's true load-bearing capacity.

Many customers see “Max Load: 100kg” in product manuals and assume it can stably transport 100kg loads continuously. However, the reality is:

Static Load only indicates the maximum weight that structural components (chassis, hubs, suspension) can withstand without permanent deformation while the robot is stationary;

Dynamic Load is the critical factor—it involves multiple elements including motor torque, gear reduction ratio, battery output capacity, inertial forces, and acceleration/deceleration response.

For example:

A chassis rated at 100kg may experience an instantaneous equivalent load exceeding 130kg when starting at 0.8m/s² acceleration under full load, or when operating on a 3° incline. If the motor or driver lacks sufficient margin, consequences range from speed reduction alarms to complete burnout of the electronic control module.

Recommendations:

For standard warehouse scenarios (flat surfaces, ≤1 m/s, frequent starts/stops), select the chassis rated load based on “peak operating load × 1.25–1.4”;

For operations involving slopes (>1%), high speeds (>1.2 m/s), or high-cycle tasks, increase the safety factor to 1.5 or higher.

2. Neglecting Chassis-Body Compatibility

Some customers, seeking to reduce costs, tend to purchase “universal” all-terrain chassis, expecting a single unit to handle diverse tasks like picking, transporting, and docking. However, different operational zones—such as high-bay warehouses, narrow aisles, cold chain areas, and human-machine mixed environments—impose distinct requirements on the chassis' navigation precision, body width, temperature control capabilities, and safety ratings.

Many customers install their own racks, lifting mechanisms, or roller modules after purchasing the chassis, resulting in:

Shifted center of gravity, causing skidding during turns;

Vibrations from the superstructure trigger navigation sensor drift.

Electrical interface incompatibility requires additional adapter boards.

The chassis is not a “flatbed truck” but rather the foundation for the entire vehicle's motion and sensing systems. Its structural rigidity, center-of-gravity design, vibration-damping characteristics, and power supply capacity directly determine the stability of the upper-level systems. To better serve our customers, we provide a standardized modular upper-body interface (including mechanical locating pins, quick-connect electrical interfaces, and CAN/RS485 communication channels).

As a professional robot chassis manufacturer, we emphasize that load capacity is not a single parameter, but rather a systematic engineering solution encompassing mechanical design, electrical control, algorithms, and scenario adaptation. Only by starting from real-world operating conditions and conducting a comprehensive evaluation that integrates dynamic margin, interface standards, and cluster collaboration capabilities can one select a truly reliable, efficient, and sustainably evolvable robot chassis solution.