Electrified Monorail Systems (EMS)

Design of Electrified Monorail Systems (EMS)

An EMS system is an overhead electrified monorail conveyance conveyor that is typically mounted on building trusses or column supported structure consisting of individual motorized carriers that move independently throughout a system that can be diverted, and converged to various paths by conveyor track switches.

The EMS carrier has a self-contained motorized trolley called a tractor or drive trolley which drives the trolley around rails. The rails are made from high strength extruded aluminum and are supported by yokes that connect to the system support steel. The tractor can be used in single application or can be connected to a combination of idle trolleys typically 2-4 trolleys. A load bar connects the trolleys to the various combinations to what is called a tractor assembly. The tractor assembly load bar has a pivot unit assembly that connects the tractor assembly to the carrier.  Carriers are specifically designed for the application and carrier movement from station to station can be automatic or operator release as required by the process. Each carrier could include VFD or servo motor controlled lift and rotate features for ergonomic access by the operators.

Power and control signals are delivered to the carriers through a brush / conductor bus rail system that is integral to the aluminum track. Power for the carrier trolley can also be supplied with induction power and communication eliminating all maintenance of typical conductor bars and brush systems. Non-contact communications with carrier controls to the main PLC is through the iDAT communication modules. On board PLC smart controls and variable speed for each carrier is achieved with open source controls that seamlessly interface the power unit and the main system PLC controls. Coded rail throughout the system provides exact positioning of every carrier.

The electrified monorail overhead conveyor systems is widely used in many industry sectors: automotive assembly lines, product transport, process automation, surface finishing, vehicle body shop, manufacture plant, distribution and logistics, production line and so on.

Features & Advantages of Electrified Monorail Systems (EMS)

Model: Standard Duty (180mm), Heavy Duty (240mm),

Types: Lightweight EMS Electrified Monorail Systems for the transport of smaller components up to 500 kg, such as doors, cockpits, engines and other assemblies; Heavy-duty EMS Electrified Monorail Systems with a payload capacity of up to 3,000 kg for transporting bodies. We have produced special designs up to 6 tons.

Loading weight: 1000lbs, 1500lbs, 3000lbs, 3500lbs, 4500lbs per trolley/pallet.

Aluminum track: Aluminum extrusion

Aluminum track size:

A. 180x60mm Standard Modular

B. 240x80mm Heavy-duty ASI Modular

Two and Four Load Trolley Systems Are Available

Vehicle: two-vehicle train, four vehicle train

Communication method: DNET, ENET

Control system: Program PLC control

Wide Range of Speeds: 1~30m/min, speed can be infinitely adjusted with frequency converter

Quiet Operation, clean, energy efficient

High flexibility, low maintenance

Modular design computer or programmable controls

High strength aluminum track

Modular Design (FATA Lean EMS)

Loading capacity: 500kg, 1000kg, 1500kg, 2000kg, 3000kg, 4000kg, 5000kg, 6000kg 1ton 2ton 3ton 5ton 6ton.

Onboard intelligence: processor, sensors, tracking

Speed Control: speeds, spacing, pacing

Agility: capable of accumulating around corners

Modular Track Assembly: pre-assembled and pre-tested

Modular Tractor Assembly: pre-assembled and quickly installed in field

Connectorized Design: quick start-up and disassembly for all applications

Domestic Sourcing: accessibility of critical parts

In-House Test Loop: design-build projects are tested prior to installation

Configurable: customizable to any unique specifications and applications

Positioning Tolerance: +/- 1mm for advanced systems

Organizational Experience

Permanent data communication via bus systems enables short reaction times and continuous adaptation to the material flow quantity.

Power: Most common system power requirement is 480 VAC 3-phase.  EMS systems can also be design with 208 VAC 3-phase using a step down transformer from 480 VAC.

Computer interface for more detailed diagnostics

Parameter module for fast startup and device replacement

This electrified monorail overhead conveyor system also provides high speeds and acceleration with sturdy construction and low noise emission.

Applicable industries: Electrified Monorail Systems(EMS) for automotive production, final assembly, powder coating line, spray painting line, automobile industry, workshops, manufacturing plant, automotive industry, paint finishing and assembly lines, surface treatment industry, etc.

Benefits & Advantages of Electrified Monorail Systems (EMS)

Routing on your plant floor can be achieved on a quiet, clean and safe EMS conveyor system. YUANDA Electrical Monorail System carriers travel from station to station for component assembly and required torque of fasteners.

Designed and manufactured with onboard intelligence, YUANDA’s EMS controls permit rapid point-to-point product movement in your facility, quickly and easily allowing you to handle incoming material and saving you time and money. Also, electric monorail system provides for tight speed control in production areas and features state-of-the-art components, allowing for future expansion.

Simple to maintain, the EMS system is constructed with minimal wires and zone cuts, and also features an intelligent tractor. For added efficiency, product radio-frequency identification can easily be added, providing for quality control tracking of your product and facilitating custom processes through automation. Our company offers both a contact and contactless (induction power) solution.

The electrified monorail system(EMS) with climbing capability allows for more flexible line layouts at lower investment costs and higher plant throughputs, This climbing electrified monorail system allows loads of up to 1,000 kg to be transported over inclines without external climbing aids.

Technical Data & Technical Specifications of Electrified Monorail Systems (EMS)

* Electrified Monorail Systems (EMS) specifications may be subject to change without notice. Powder coat paint color to match customer specifications

Different Types of Monorail Overhead Conveyor System

The electrified monorail system(EMS) is an overhead conveyor system for in-plant material flow. It consists of independent vehicles that run freely on the track system. The running rail is suspended from the ceiling by brackets. The track system allows vehicles to be operated continuously or in cycles. The modular design enables short assembly times as well as various load configurations. High speeds with excellent stopping accuracy thanks to frequency-controlled steering with integrated path measurement set this system apart.

YUANDA offers two types of EMS Control System Methods (Standard and Lean). The standard methods are designed with off-board and on-board PLC controls. Standard EMS overhead conveyor systems are supplied with two different control philosophy. The first method is a simple proximity switch and rail cut technology that provides signals to sense carrier presence to the system’s main PLC to start and stop the carrier. The second method uses encoded rail or bar code on the EMS track and RF communications to the system’s main PLC. In this method the main PLC can stop a carrier at programmed locations derived from the encoded rail. Both methods require electronics with PLC logic on-board the carrier, communications protocols (RF) back to a main PLC that would direct traffic of the system is also available.

The bespoke EMS is a Modular Rail Bus Controlled System with only off-board PLC controls. The main principle of this design is controlling track segments on which the tractor drives the trolley around the rails, thus eliminating the need for an on-board PLC trolley control box. The track is designed as a module with any distributed control motor starters with DNET, ENET or similar communication method, as directed by the facility, carrier enter and stop switch, cords and trunk cables. The electric motor starter controlled from the off board main PLC/PDP set provides power and control to the track that drives the tractor and starts and stops the carrier from the condition of the entering and exiting track segment’s enter and stop switch. The control of the track is modular and emulates a skid conveyor system simplifying the programming of the EMS system.

With single shuttle or double shuttle, the EMS conveyor can be designed as single shuttle electrified monorail system, and twin shuttle electrified monorail system. The Twin-Shuttle EMS offers space for two pallets in parallel next to each other and can thus transport up to two tons in weight. The two pallets can even be loaded and unloaded independently and fully automatically by traveling suspension chain conveyors or roller conveyors. With different functions, the EMS can be grouped as Order Picking Electrified Monorail System(EMS), and Climbing Electrified Monorail System(EMS). With different hangers, it can be pallet monorail overhead conveyor, pallet conveyor system. If installed as ground-based, it can be floor mounted inverted electrified monorail system or electrified floor track systems. Sorted by work grade, it can be made as light duty electrified monorail system and heavy duty electrified monorail system.

These different types of electrified monorail system(EMS) are used for automotive, surface finishing, powder coating industry, vehicle body shop, final assembly, distribution centers and logistics, general manufacturing plant, workshop production line.

Electrified Monorail Systems Components, Accessories and Electrified Monorail Overhead Conveyor Systems Spare Parts

The electro monorail system consists of an aluminum monorail layout on which autonomous hangers can run. The EMS loop can be enhanced with switches, elevators or transfer systems to create a network. Made to suit, our Monorail networks are made of standard components, suspensions and aluminum profiles. Our electrified monorail conveyor systems are suitable for all overhead and inter-building logistics.

Decline Safety Conveyor – Used in delivery systems to prevent carrier runaway conditions where workers are present.

Production Chain Assists – Used in production build lines to maintain a constant speed and distance between jobs.

Positioners – Used to accurately position a carrier in automated processes such as lowering a carrier with part onto a fixture or to transfer part off of the carrier and onto another conveyance system.

Switches – Track, Shuttle & Cross– These products can be used in all aspects of an EMS system. A track switch changes the carrier’s path by diverting and/or merging paths. Shuttles transfer carriers to multiple parallel lanes. A cross switch is as an intersection when a carrier must cross another path.

Vertical Chain Assists – Used in delivery systems to assist carrier travel vertically up curves.

Vertical Drop Lift – Used to transfer a carrier from one elevation to another.

Vertical Lift Stations – Used in automated processes to lower the carrier w/ part onto a fixture. Typically used in welding applications.

De-clutch/ Clutch Device (Thumper Assembly) – Used in-conjunction with production chain assists to de-clutch the carrier’s motor/gearbox allowing the production chain to convey the carrier at slow production speeds.                    

Control System

The EMS tractor carriers all of the intelligence for a simple system and requires only the addition of external power distribution to make a complete system. In more complex systems, which require sorting or routing, a supervisory processor is added which communicates with the plant manufacturing system.

•Common On-Board Components: PLC, VFD. Typical brand names include Mitsubishi, Siemens and Omron, Honeywell, Sunx.

•Common System Control Components: Inductive devices, Sortation / Automatic Identification devices: RFID

•Central Panel Functions: Power Distribution, Power Contractors, E-Stop Relays, Supervisory Control PLC, Zone Control, Local I/O

Hanger and pallet- YUANDA supplies and develops hangers with stroke scissors with a stroke of up to 4.5 m in a variety of different designs, each pallet individually adapted to customer needs. This pallet conveyor allows you to set up optimum ergonomic conditions for every work cycle and the transfer of logistics and transport routes inside the factory.

Other components include: lifting and lowering stations, controllers and sensors on the vehicles, inductive sensor for distance monitoring, 7-segment display and 16 status LEDs on the controller, electric cars and control components. This system provides high speeds and acceleration with sturdy construction and low noise emission.

EMS (Electrified Monorail System) is built to ensure that product is always moved in the safest, quietest, cleanest and most efficient way possible. The EMS system arrives at your facility pre-assembled and pre-tested for a quick system startup.

Electrified Monorail Overhead Conveyor System Application

This type of EMS system allows for a wide range of conveyor speeds varying from 8 to 400 fpm, allowing the carrier to accelerate, decelerate, creep into an exact position for automated workstations, reverse travel, travel on defined production centers, travel at very high speeds or variable speeds, accumulate, transfer and storage elevation changes, etc.

In addition, the Electrified Monorail System can have an on board computer ensuring decision making for alternate routings without relying on the preferred centralized conveyor system.

The Electrified Monorail Systems overhead conveyor is widely used for surface treatment industry, automotive industry, workshops, industrial paint lines, assembly operations, transfer and transport.

We have many different models of Electrified Monorail System(EMS) for sale, contact us online now for more details.

Electrified Monorail Systems(EMS) Manufacturer in China

YUANDA is a China company in Electrified Monorail Systems (EMS) industry with installations for many projects. We have over 200 EMS installations totaling over 100 miles of track in a variety of applications such as delivery, production areas and automated processes. We have exported to many countries including: Saudi Arabia, Australia, European, United States, Canada, Indonesia, Mexico, Chile, Peru, UAE, Malaysia, Middle East, the United Kingdom, EU, etc. We also take care of your plant on turnkey basis after commissioning and installation. With our extensive customer service offer we ensure high reliability and fast problem solving.

We offer customizable, complete automation solutions! For complex handling, transport or manufacturing tasks, we development, design and deliver specialized solutions. If you want to buy an Electrified Monorail Systems(EMS) for your workshop, please contact us now to learn more about our conveyor designs and discuss your own needs.