Description
Vahle Smart Collector
VAHLE Smart Collector – Predictive Maintenance with an Intelligent Collector
Unplanned stoppages of the automated handling systems used on modern production lines can have serious consequences. When these systems fail, production can stop completely and cause high sales losses; when a fault takes long to locate, costs can reach uncontrollable levels.
To solve this problem, VAHLE developed the world’s first intelligent current collector — the Smart Collector. Equipped with special sensor technology, this innovative system records its linear and circular movements with sensors and transmits the data to the Main Unit for analysis. There the data is analyzed using VAHLE’s Intelligent Dynamic Anomaly Analysis (IDAA) method, monitoring the condition of the entire conductor rail system in real time during operation.
The Smart Collector’s current-collector arms are equipped with neodymium magnets. Thanks to contactless magnetic-field measurement, even the smallest wear-related movement changes in the conductor system are detected by the sensors. This means potential anomalies are identified at an early stage, maintenance cycles are planned optimally, and plant availability and efficiency are significantly increased.
The Smart Collector was developed especially for electrified monorail systems (EMS) and automated storage / retrieval systems (AS/RS), but can also be used in different plant types. Thanks to its intelligent structure, the system is fully compatible with various VAHLE conductor rail systems, data communication and positioning solutions.
Smart Collector
Award-Winning Technology – Product of the Year
The Smart Collector sets new standards in safety and efficiency wherever power and data flow.
Thanks to VAHLE’s innovative engineering, this technology has been recognized with international awards.
Smart Collector
Current Collector
3D sensors integrated into the Smart Collector’s current-collector arms precisely measure the stroke and deflection movements the system performs during operation.
The presence of these sensors does not affect the collector’s power transmission performance in any way.
The collected movement data is transmitted to the Main Unit for analysis.
Smart Collector
Main Unit
The measurement data from the collector arm is processed in real time in the main unit using the Intelligent Dynamic Anomaly Analysis (IDAA) method.
By evaluating the instantaneous condition of the system, this analysis enables early fault detection and maintenance optimization.
Thanks to its flexible structure, the main unit has variable interfaces compatible with different Positioning and Data Communication Systems.
Smart Collector
Data Transmission
When the main unit detects a repeatable anomaly, it transmits this information to the certified VAHLE data centre.
Data transfer is carried out via LTE, SMGM (slotted microwave guide) or other VAHLE communication infrastructures.
The system does not continuously transmit or store data; it only sends data at defined event moments — keeping data security at the maximum level.
Smart Collector
Software
The analyzed measurement data is visualized through VAHLE’s dedicated software.
This software lets operators monitor the instantaneous condition of the plant (Condition Monitoring) and manage maintenance plans digitally.
The software interface is accessible from all terminals, including desktop, tablet and mobile devices.
Technical Data – Electrical Properties
| Specification | Value |
|---|---|
| Operating voltage | 24 VDC |
| Max. current requirement | 5 A |
| Max. data transmission rate | 100 MBit/s |
| Protection class | IP54 |
Technical Data – Mechanical Properties
| Specification | Value |
|---|---|
| Max. travel speed | 300 m/min |
| Operation with funnel | Applicable |
Technical Data – System Properties
| Specification | Value |
|---|---|
| Compatible conductor systems | U10, VKS10 |
| Current collector types | KDS 2/40, KUFR 2/40, KESR, KESL |
| Data access | Progressive Web App (PWA) |
| Max. installation time | 90 minutes |
Operating Conditions
| Specification | Value |
|---|---|
| Operating temperature | -30°C to +55°C |
| Application area | Indoor systems |
Catalogs and Brochures
User and Installation Manuals
Get a Quote Tailored to Your Needs!
Fill in the short form and our team will quickly get back to you with a project-specific solution and delivery time.
PRODUCT DETAILS
VAHLE Smart Collector – Predictive Maintenance with an Intelligent Collector
Unplanned stoppages of the automated handling systems used on modern production lines can have serious consequences. When these systems fail, production can stop completely and cause high sales losses; when a fault takes long to locate, costs can reach uncontrollable levels.
To solve this problem, VAHLE developed the world’s first intelligent current collector — the Smart Collector. Equipped with special sensor technology, this innovative system records its linear and circular movements with sensors and transmits the data to the Main Unit for analysis. There the data is analyzed using VAHLE’s Intelligent Dynamic Anomaly Analysis (IDAA) method, monitoring the condition of the entire conductor rail system in real time during operation.
The Smart Collector’s current-collector arms are equipped with neodymium magnets. Thanks to contactless magnetic-field measurement, even the smallest wear-related movement changes in the conductor system are detected by the sensors. This means potential anomalies are identified at an early stage, maintenance cycles are planned optimally, and plant availability and efficiency are significantly increased.
The Smart Collector was developed especially for electrified monorail systems (EMS) and automated storage / retrieval systems (AS/RS), but can also be used in different plant types. Thanks to its intelligent structure, the system is fully compatible with various VAHLE conductor rail systems, data communication and positioning solutions.
Smart Collector
Award-Winning Technology – Product of the Year
The Smart Collector sets new standards in safety and efficiency wherever power and data flow.
Thanks to VAHLE’s innovative engineering, this technology has been recognized with international awards.
Smart Collector
Current Collector
3D sensors integrated into the Smart Collector’s current-collector arms precisely measure the stroke and deflection movements the system performs during operation.
The presence of these sensors does not affect the collector’s power transmission performance in any way.
The collected movement data is transmitted to the Main Unit for analysis.
Smart Collector
Main Unit
The measurement data from the collector arm is processed in real time in the main unit using the Intelligent Dynamic Anomaly Analysis (IDAA) method.
By evaluating the instantaneous condition of the system, this analysis enables early fault detection and maintenance optimization.
Thanks to its flexible structure, the main unit has variable interfaces compatible with different Positioning and Data Communication Systems.
Smart Collector
Data Transmission
When the main unit detects a repeatable anomaly, it transmits this information to the certified VAHLE data centre.
Data transfer is carried out via LTE, SMGM (slotted microwave guide) or other VAHLE communication infrastructures.
The system does not continuously transmit or store data; it only sends data at defined event moments — keeping data security at the maximum level.
Smart Collector
Software
The analyzed measurement data is visualized through VAHLE’s dedicated software.
This software lets operators monitor the instantaneous condition of the plant (Condition Monitoring) and manage maintenance plans digitally.
The software interface is accessible from all terminals, including desktop, tablet and mobile devices.
Technical Data – Electrical Properties
| Specification | Value |
|---|---|
| Operating voltage | 24 VDC |
| Max. current requirement | 5 A |
| Max. data transmission rate | 100 MBit/s |
| Protection class | IP54 |
Technical Data – Mechanical Properties
| Specification | Value |
|---|---|
| Max. travel speed | 300 m/min |
| Operation with funnel | Applicable |
Technical Data – System Properties
| Specification | Value |
|---|---|
| Compatible conductor systems | U10, VKS10 |
| Current collector types | KDS 2/40, KUFR 2/40, KESR, KESL |
| Data access | Progressive Web App (PWA) |
| Max. installation time | 90 minutes |
Operating Conditions
| Specification | Value |
|---|---|
| Operating temperature | -30°C to +55°C |
| Application area | Indoor systems |
Catalogs and Brochures
User and Installation Manuals
Get a Quote Tailored to Your Needs!
Fill in the short form and our team will quickly get back to you with a project-specific solution and delivery time.
