Electrified monorail system (EMS) automation solution

  • Orange electrified monorail system

Electrified monorail systems require the very latest technical standards. We're able to define and establish these innovations with our MAXOLUTION® automation solutions. With the help of extensive software functions, we can ensure your start of production runs smoothly and that your system exhibits high availability.

Electrified monorail system (EMS) – our portfolio:

  • The MAXOLUTION® solution for light-duty electrified monorail systems with half-wave control: EMS basic
  • The MAXOLUTION® solution for light-duty electrified monorail systems with WLAN communication: EMS advanced
  • The MAXOLUTION® solution for heavy-duty electrified monorail systems with safe communication: EMS safety

Your benefits

  • Everything from a single source

    The complete control and drive system, from the stationary control level to the controllers and sensors on the vehicles
  • Reliable planning and minimized risk

    Thanks to a certified project team, simulation and emulation with MOVIVISION®, startup, production support and project acceptance
  • Perfectly tailored to your production requirements

    The modular systems are integrated into your system using flexible MOVIVISION® software solutions
  • Data transparency and high system availability

    With intelligent Drive Radar® software solutions for condition monitoring and predictive maintenance. Keeping ahead of errors!

EMS basic

Vehicle functions

EMS basic vehicle functions

Red gearmotor and gray controller on electrified monorail system
MAXOLUTION® solution for light-duty electrified monorail systems with half-wave control
MAXOLUTION® solution for light-duty electrified monorail systems with half-wave control
  • MOVIPRO® PHE basic half-wave evaluation/control for the travel drive
  • Quick diagnostics with 7-segment display and 16 status LEDs on the controller
  • Computer interface for more detailed diagnostics
  • Parameter module for fast startup and device replacement
  • Optical or inductive sensor for distance monitoring
  • Optional keypad for driving the vehicle manually

Technological schematic

Technological schematic for electrified monorail system EMS basic

Safety technology

  • Safe torque off (STO) in accordance with PL d
  • Optional safe limited speed (SLS) with integrated motor encoder and UCS safety module
  • Magnetic switch for safe range detection

Stationary communication functions

  • Half-wave modules for the track and curves

Software functions

• Easy parameterization and startup with MOVIVISION® system software

Technical data

  • Integrated drive inverter up to 1.5 kW
  • Optional: Control modules for the control and message rail
  • Can be expanded to up to 8 speeds/parameters with magnetic switches
  • Four magnetic switches / sensors can be connected directly, or up to 6 with optional expansion

EMS advanced

Vehicle functions

EMS advanced vehicle functions

Technological schematic for electrified monorail system EMS advanced
MAXOLUTION® solution for light-duty electrified monorail systems with WLAN
  • Powerful MOVIPRO® PHE advanced controller with WLAN communication to stationary segment controller
  • Integrated inverter for travel axis – option to connect an additional decentralized inverter
  • Position detection by means of a 2D barcode reader system
  • Parameter memory for fast startup and device replacement
  • Quick diagnostics with 7-segment display on the controller
  • Centralized, detailed vehicle diagnostics with MOVIVISION®
  • Optional keypad for driving the vehicle manually

Technological schematic

Technological schematic for electrified monorail system EMS advanced

Safety technology

  • Safe torque off (STO) in accordance with PL d
  • Optional safe limited speed (SLS) with integrated motor encoder and UCS safety module

Functions of the stationary system

  • System/segment controller for vehicle coordination and diagnostics
  • Reliable and shielded WLAN communication in slotted waveguide
  • Visualization and operation on Windows-based systems such as HMI panels or computers
  • Maintenance-free and wear-free inductive energy transmission available as an option
  • Optional switch control with MOVIPRO® PHE advanced
  • Optional: support rail with integrated slotted waveguide

Software functions

  • Coordinate and monitor the track using the intelligent MOVIVISION® system software (e.g. continuous operation with different cycle lengths, collision monitoring, synchronous travel, routing, vehicle query)
  • Perform parameterization and diagnostics using a distributed server-client application with authorization concept
  • Parameterizable interface for connection to the PLC
  • Detailed diagnostics
  • Condition monitoring
  • Optional: virtual startup using 3D simulation based on real device software

Technical data

  • Drive inverter up to 1.5 kW for travel drive
  • Optional auxiliary axis
  • Sizes up to 15 kW
  • Continuous WLAN communication in shielded slotted waveguide
  • Positioning accuracy up to +/- 2 mm possible
  • One segment controller coordinates up to 50 vehicles, up to 10 segment controllers can be cascaded

EMS safety

Vehicle functions

Vehicle functions for EMS safety

Electrified monorail system EMS safety with black vehicle body
MAXOLUTION® solution for heavy-duty electrified monorail systems with safe
  • Powerful MOVIPRO® PHC controller
  • Safe WLAN communication from vehicle to stationary safety controller
  • Integrated inverter for lifting axis – additional decentralized inverters can be added for travel axis and additional axes
  • Safe position detection by means of a 2D barcode reader system
  • Quick diagnostics with 7-segment display on the controller
  • Parameter memory for fast startup and device replacement
  • Centralized, detailed vehicle diagnostics with MOVIVISION®
  • Optional keypad for driving the vehicle manually

Technological schematic for electrified monorail system EMS safety

Technological schematic for electrified monorail system EMS safety

Safety technology

  • High-performance safety controller MOVISAFE® HM31 – SIL 3/PL e

Available safety functions in accordance with PL d:

  • STO, SLS, SLP, and Safe Brake Control (SBC) for the lifting axis
  • STO, SLS, and SLP for the travel and auxiliary axes
  • System EMERGENCY STOP via safe communication
  • Downloading the control and safety parameters via WLAN
  • Optional: safe distance monitoring (SDM®) between vehicles in the assembly area

Stationary communication functions

  • System/segment controller for vehicle coordination and diagnostics
  • Reliable and shielded WLAN communication in slotted waveguide
  • Visualization and operation on Windows-based systems such as HMI panels or computers
  • Optional switch control with MOVIPRO® PHE advanced

Software functions

  • Coordinate and monitor the track using the intelligent MOVIVISION® system software (e.g. continuous operation with different cycle lengths, collision monitoring, synchronous travel, routing, vehicle query)
  • Perform parameterization and diagnostics using a distributed server-client application with authorization concept
  • Parameterizable interface for connection to the PLC
  • Detailed diagnostics
  • Condition monitoring
  • Optional: virtual startup using 3D simulation based on real device software
  • Optional: Motion Profile Manager for quickly changing the lift, turn, and basin profiles and envelopes

Technical data

  • Drive inverter up to 22 kW for lifting axis
  • Drive inverters up to 4 kW for travel axes and optional auxiliary axes
  • Continuous safe WLAN communication in shielded slotted waveguide
  • Positioning accuracy up to +/- 2 mm possible
  • One segment controller coordinates up to 50 vehicles, up to 10 segment controllers can be cascaded
  • PFF-HM31 PLe safety controller
  • Connection to PROFIsafe, CIP Safety and others

Why use MAXOLUTION® EMS solutions for your automotive production?

Light-duty EMSs with half-wave control

EMS basic

  • Proven solution for simple transport tasks with segmented control using half-wave signals
  • Travel axis only
  • Fast and cost-effective startup thanks to parameterization software and parameter memory
  • Can be retrofit into existing EMS conveyor lines – implemented quickly and reliably by our service team

Light-duty EMSs with WLAN communication

EMS advanced

  • More flexible – more user-friendly
  • Light-duty EMS with broadband, continuous communication for addressing vehicles individually
  • Travel axis plus optional additional axis
  • Complete drive system: segment controller, communication, positioning system, mobile control, and much more
  • Optional: Perfectly tuned mechanical components: support rail with integrated slotted waveguide
  • Virtual startup with simulation and emulation
  • Easily keep track of your system – DriveRadar® / condition monitoring & predictive maintenance

Heavy-duty EMSs with safe communication

EMS safety

  • Fast, precise and safe
  • Integrated multi-axis function for driving, lifting and turning
  • Complete drive system: segment controller, communication, positioning system, mobile control, and much more
  • Virtual startup with simulation and emulation
  • Extensive safety functions in accordance with SIL3 (PL d/e)
  • Dynamic, safe distance monitoring (SDM®) for optimizing production cycle lengths
  • User can easily edit and change lifting heights
  • Easily keep track of your system – DriveRadar® / condition monitoring & predictive maintenance
Contact us

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