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
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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!
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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
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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 communication
  • 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
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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 communication
  • 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
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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
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