Electrisch Monorailsysteem

ELECTRIC MONORAIL SYSTEM (EMS)

A transport system that automates and accelerates the internal flow of pallets with self-driving carts following electrified rails.

Automated solution for transporting pallets at high speed, ideal for long distances

The Electric Monorail System uses powered carts that move pallets along a closed circuit of electrified rails (mounted on the floor or hanging from the ceiling). It is a fully configurable solution, where circuits of varying complexity and length can be designed to quickly and efficiently connect distant areas.

The carts are controlled by software that regulates traffic and determines the optimal route. They travel along the circuit to move pallets between different loading and unloading points. Thanks to their speed, Mecalux’s electric monorail systems can move goods smoothly in all types of warehouses and production centers.

ADVANTAGES OF THE ELECTRIC MONORAIL SYSTEM

High speed: the carts reach speeds of up to 100 m/min with load and 120 m/min without load. The system is faster than conveyor belts and can deliver a higher flow of pallets per hour.
Long distances: the Electric Monorail System is ideal for automating the transport of pallet loads between distant points.
Intelligent: the control software monitors traffic on the circuit in real time and manages the loading/unloading needs to distribute tasks among the available carts. The system assigns the fastest route to each cart and dynamically adjusts the route to avoid bottlenecks.
Discontinuous autonomous movement: the carts move independently, allowing them to follow different routes within the same circuit and take shorter or alternative paths.
Fully configurable circuits: circuits of varying complexity can be designed with straight and curved sections, switches, shorter paths, parallel tracks, parking spaces, and maintenance zones.
Flexibility and scalability: new carts can be added, or the circuit can be expanded in case of increased production. Additionally, new loading and unloading stations for pallets can be added, or the location of existing stations can be modified.
Quiet and safe: the cart design and the use of advanced acceleration and braking techniques ensure smooth and quiet operation. The carts are always in contact with each other, maintaining a safe distance.
Energy-efficient: thanks to the use of parking spaces, the number of carts in circulation can be adjusted to match the workload, significantly reducing energy consumption.
Easy maintenance: the carts are diverted to a secondary circuit for maintenance, allowing the rest of the system to operate normally.

APPLICATIONS OF THE ELECTRIC MONORAIL SYSTEM FOR PALLETS

Agile and versatile transport solution to automate the pallet flow

The system is flexible, can cover long distances, and follow a wide variety of routes. This makes it suitable for various functions in different types of warehouses and production centers.

Connecting parts within a warehouse

The Electric Monorail System automates the pallet flow between different parts of the warehouse.

Connecting the warehouse with production

The Electric Monorail System connects the production lines with the warehouse.

Connecting different warehouses

The Electric Monorail System is ideal for connecting warehouses in separate halls, as long circuits can be created.

Supplying the shipping area

The Electric Monorail System speeds up the transport of pallets to the shipping area and sorting them into preloading channels.

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See also

AUTOMATIC TRILATERAL WAREHOUSE CRANES

BIG BOX RACK M7

PALLET RACKS

PALLET ROLLER CONVEYOR

Drive-in Racking

MOVIRACK MOBILE SHELVING

FAQ

Question - answer

What is the Electric Monorail System?

The Electric Monorail System is an automatic, discontinuous pallet transport system consisting of carts driven by an electric motor and moving along a closed circuit of electrified rails. The carts travel along the rails, moving pallets between the various loading and unloading stations along the route. This solution is highly maneuverable and efficient whereby long distances can be covered, internal transport of palletized loads is significantly improved, and the requirements of different types of warehouses can be met.

How fast do the carts go?

The trolleys running on the monorails have a maximum speed of 100 m/min with load and 120 m/min without load.

What is the maximum load on the carts?

Each cart can carry a maximum load of 1,500 kg.

What types of pallets can the electric Monorail system transport?

The carts are compatible with 800 x 1,200 mm, 1,000 x 1,200 mm and 1,200 x 1,200 mm pallets and 600 x 800 mm half pallets. They can also be adapted to handle pallets of other sizes according to customer requirements, such as GMA pallets (or American pallets).

At what temperature can an electric Monorail system operate?

The electric Monorail system is suitable for a wide temperature range: from -30 °C to +40 °C. It is therefore the perfect solution for automating the flow of palletized loads in refrigerated and freezer rooms.

How does the electric Monorail system work?

Software monitors traffic on the Electric Monorail system in real time to distribute tasks among the various carts. The program receives work orders from the Warehouse Management Software and distributes them to the trolleys. Thus, the software tells them which loading and unloading stations to call at and the most efficient route to complete the task.

What is the difference between the electric Monorail system with guide rails on the floor and with overhead wires?

In an overhead electric Monorail system, the aluminum rails on which the self-propelled carts travel are attached to the ceiling or to a raised structure. In contrast, in a floor-mounted electric Monorail system, the rails are attached to the warehouse floor. Overhead rails are used in the electric Monorail system when the warehouse floor must remain free of obstacles to allow for other traffic or for cleaning in businesses with strict hygiene requirements, such as in the food industry. They are also the ideal solution for buildings where the floor is not nice and level or does not have the required strength. Floor-mounted rails are often used for medium-sized electric Monorail systems. They are very easy to install and offer a small turning radius.

What is the difference between the electric Monorail system and pallet conveyors?

The Electric Monorail System, like a pallet conveyor, is a system designed to automate the internal flow of goods on pallets. Conveyor belts, however, are continuously moving, allowing them to transport large volumes of pallets simultaneously. Unlike the electric Monorail system, conveyor belts can also serve as a buffer. Then pallets are temporarily stored on the conveyor to create a temporary buffer or regulate the flow of goods. The electric Monorail system, on the other hand, is a discontinuous transport system that is also faster than conveyors: they can reach speeds of 100 m/min with load, compared to 20 m/min for conveyors. The electric Monorail system is therefore the right choice to design medium or long circuits or to move pallets as fast as possible.

How does the electric Monorail system differ from autonomous mobile robots?

The Electric Monorail System and autonomous mobile robots (AMR) are automation solutions designed to transport individual loads between two points. The Electric Monorail System uses carts that transport pallets along a closed and defined circuit. AMRs, on the other hand, move freely through the warehouse. They follow dynamic routes adapted to each task and do not follow closed circuits or restricted work areas. While autonomous mobile robots are easier to integrate into the warehouse set-up than the electric Monorail system (no rails or safety fences need to be installed), the electric Monorail system is usually the ideal solution when pallets are in high demand. Indeed, it would require a very large fleet of autonomous mobile robots to deliver that same volume.

Are the electric rails of the electric Monorail system suitable for the warehouse setup?

Yes, the electric Monorail system is very versatile and can be adapted to the characteristics of each warehouse. Thanks to this flexibility, it is possible to adapt the rails to specific requirements. For example, adding curves or switches in between to create shorter paths, parallel tracks, diagnostic stations or parking areas.

Can several buildings be connected by an electric Monorail system?

Yes. An electric Monorail system can be used to connect warehouses in separate halls. To do this, a tunnel or bridge is usually built to house the circuit connecting the two buildings.

Is the electric Monorail system safe?

Yes, the electric Monorail system is equipped with various safety features, such as photocells, stops and bump blocks. This allows the trolleys to move smoothly and stably along the track. In addition, the track is demarcated by a fence to prevent collisions with people or other machinery.

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