Final Assembly

Powerful Energy and Control for Heavy-Duty Material Transport

Heavy EMS systems are indispensable in the final assembly of vehicles. They transport vehicle bodies safely and ergonomically through each phase of the assembly process. With our energy transmission solutions, such as conductor rails and inductive power systems, we ensure a continuous power supply even under demanding production conditions. These systems not only ensure maximum uptime but also boost production efficiency and worker ergonomics, creating a smoother, more reliable assembly process.

In final assembly, real-time data is critical for precise coordination. Our cutting-edge data transmission technologies enable seamless communication between vehicle carriers and central control systems. This ensures every movement is perfectly synchronized, improving safety, streamlining workflows, and maximizing efficiency throughout the production line.

Automation and safety are at the heart of Heavy EMS systems. Our control solutions monitor every movement of the vehicle carriers, ensuring safe distances and precise positioning. With a reliability rate of over 99%, we meet the high standards of the automotive industry, minimizing downtime and preventing production losses.

Tailored Solutions for You: 

• Our Conductor Rails 0815 Pro EMS and Inductive Power Systems ensure reliable performance in demanding final assembly environments.
• For precise control, the Series 89x LJU controls, including certified safety boxes, provide a robust, safe and secure solution tailored to the needs of heavy-duty applications.
• Data transmission options include Railbus, ideal for standard applications with basic safety requirements, and ProfiDATcompact, which meets the stringent safety demands of complex systems.
• In scenarios where conventional methods are unsuitable, Wireless Communication Solutions ensure seamless data flow, offering flexibility and reliability for specialized Heavy EMS setups.

Innovative Systems for High-Performance Monorail Transport

Electric Monorail Systems (EMS) are essential for transporting components like doors, cockpits, and engines in automotive production. Our solutions, such as high-performance conductor rails and advanced inductive systems, provide a reliable energy supply, keeping operations smooth and eliminating costly downtime. Built to meet the demanding standards of the automotive industry, our solutions ensure uninterrupted energy flow, even under heavy loads and high speeds.

Real-time data is critical to keep EMS carriers running safely and efficiently. Our cutting-edge data transmission systems deliver precise communication between carriers and control systems, ensuring smooth integration into production lines. This level of accuracy optimizes movement control and supports maximum efficiency across every step of the process.

Automation and safety are key to efficient production. Control solutions such as our LJU control technology monitor and control all movements of EMS carriers to ensure safe and efficient operation. These easy-to-maintain control boxes allow faults to be rectified quickly, minimizing downtime and improving overall line productivity.

Tailored Solutions for You: 

• The 0815 Pro EMS, 0811 SingleFlexLine Conductor Rails and Inductive Power Supply Systems deliver efficient and reliable energy transmission.
• For control requirements, the Series 87x provides a robust solution for straightforward applications like bodyshops, while the Series 89x supports advanced setups such as door EMS or systems requiring multi-axis control.
• Series 83x, 87x, and 89x offer seamless retrofit options for modernizing older equipment.
• Our data transmission solutions range from Halfwave and PCM for basic needs, to the sophisticated Railbus for standard operations, and ProfiDATcompact for complex systems requiring high safety standards.
• When traditional methods fall short, Wireless Communication Solutions ensure data transfer in unique EMS applications.

Powering Smart Mobility: Solutions for AGVs and AMRs

AGVs (Automated Guided Vehicles) and AMRs (Autonomous Mobile Robots) are essential for automated material transportation in factories and warehouses. While AGVs follow fixed routes, AMRs use SLAM technology to navigate dynamically and adapt to changing environments. A well-designed energy supply and data communication strategy are essential to maximize uptime and efficiency.

A reliable energy concept is key to ensuring continuous operation. Opportunity charging helps minimize battery size, weight and cost, while reducing the total number of robots needed to perform a given task. Our solutions, such as inductive charging and conductor rail systems, provide efficient power transmission, eliminating long charging breaks. Intelligent energy management, which co-designs battery size with the charging strategy, enables seamless integration into operational workflows, allowing robots to charge strategically without disrupting production.

Stable and fast data connectivity is essential for accurate navigation, process control, and fleet management. Our solutions enable real-time communication, allowing AGVs and AMRs to receive updates, optimize routes, and react dynamically to obstacles. In addition, advanced data management allows robots to enter sleep mode during downtime and wake up automatically, reducing unnecessary energy consumption. By integrating reliable energy transmission with intelligent data communication, we enhance productivity, optimize fleet efficiency, and support the seamless automation of modern intralogistics environments.

Tailored Solutions for You:

• Our all-in-one inductive charging solution WirelessCharger 3.0 ensure a reliable energy supply for high-throughput AGV/AMR operations
• Our conductive charging solutions based on KontaktCharger series and Nano+ and Enduro+ charging contact series will cover all size of AGVs and AMRs with fast rates.
• Integrated charging solutions like 0865 ChargeLine could also be provided for a dynamic charge to reduce downtime and enhance overall system efficiency.
• BatteryBlock energy storage series is provided plug-and-play with our charging solutions, for a safe and efficient charging process.
• AGVs and AMRs equipped with onboard energy storage benefit from RadioSafe, a fleet-wide emergency stop system that enhances safety, and can remotely handle sleep modes

Smart Technologies for Safe and Efficient Workflows

Efficiency, safety, and comfort are key to modern manufacturing. Conductix-Wampfler ergonomic Handling Systems create optimized workstations and assembly lines that reduce strain and increase productivity. Our solutions integrate reliable energy supply systems with tool transporters, retractors, and balancers, ensuring a seamless flow of power to effortlessly lift, rotate, and position components.

Our advanced data transmission solutions enable seamless communication between tools, equipment, and automation systems. Whether in a compact workstation or a large production facility, real-time data flow ensures that every movement is controlled, efficient, and synchronized with production requirements.

Our modular workplace systems, from single and double rail systems to jib booms and equipment cranes, provide the flexibility to adapt to any workspace. Intelligent control solutions optimize movement, streamline operations, and enhance safety. Whether in a small workshop or a high-volume production line, our expert guidance will help you design the perfect ergonomic solution for maximum performance.

Tailored Solutions for You: 

• Our BestaPower Media Supply Systems make compressed air, electrical power, and digital data available for mobile equipment.
• Tool Transporters and Equipment Carriers are the best choice for handling multiple different tools.
• Our wide range of Retractors and Balancers covers your needs when it comes to supporting weight and reducing workload when moving heavy tools.
• Spring-Driven Reels in various designs are the ideal complement for safe and ergonomically designed workstations.
• Buffers and Bumpers in various sizes and designs complete our range of solutions when energy absorption is needed.

Driving Productivity in Automated Skillet Operations

Skillet Systems are crucial to smooth and efficient final assembly. The stationary friction drives power to the platforms with precision, maintaining a smooth production flow. Our durable energy and data transmission solutions keep the platform energized, enabling ergonomic and safe lift table operation, even in tough production environments. By minimizing downtime and maximizing reliability, we deliver long-term performance that keeps manufacturing lines productive and efficient.

Fast, secure data transmission is critical for Skillet Systems' precise operation. By routing data lines underground, our solutions eliminate interference and enable real-time communication between all components. This ensures constant access to production data, streamlining monitoring and optimizing processes to keep operations running at peak efficiency.

With flexible control solutions, we enable easy adaptation of Skillet Systems to changing production requirements. Ergonomic platform height adjustment improves operator comfort and supports the production of vehicles of varying sizes.

Tailored Solutions for You: 

• Conductor Rails (0811) provide a reliable energy supply. They are customized to meet specific application needs with heavy-duty pickup guides and quick-change collector units.
• Inductive Power Systems enable seamless, contactless energy supply for modern setups.
• The Series 89x LJU controls deliver advanced control, featuring certified safety boxes to ensure secure and precise operation in demanding final assembly environments.
• For data transmission, Railbus supports standard applications with basic safety functionality.
• Our Wireless Communication Solutions are available for unique scenarios where other methods cannot be applied effectively.