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When it is time to modernize your legacy transfer car equipment, you can typically anticipate costly replacements and long periods of downtime that will negatively affect your bottom line. Our engineers felt this was unacceptable and developed the "new normal" in transfer car modernization solutions with an impressive suite of products.
Below you will find high-quality, cost-effective solutions that can be easily retrofit to any existing equipment with minimal downtime and an emphasis on safety.
Nexus BB + Optical Positioning:
The one-of-a-kind, patented Nexus BB is the only industrial data over power solution on the market. Nexus BB turns your conductor into the most secure and reliable Ethernet connection and is easily retrofit to existing systems, including; festoon, cable chain, slip ring, conductor rail, and cable reels. So, when Wi-Fi falls short, Nexus BBs secure hardwired connection prevails as the only solution for industrial network communication.
Pairing Nexus BB with Optical Positioning will offer a complete solution for positioning needs along a fixed rail. Using an optical camera to read code tape, Optical Positioning allows automated machinery to determine the exact position of moving machines or elements, allowing for safe vehicle spacing, material storage location, and position feedback. Our Optical Positioning systems are easy to quote, quickly retrofitted into existing applications, are compatible with PROFINET, EtherNET/IP, and PROFISafe, and are easy to install.
Jay Radio + RadioSafe Global Safety Stop:
The final step in our modernization solutions is with the addition of Jay Radio + RadioSafe Global Safety Stop. Jay Radio is our cost-effective, SIL 3 safety-rated bidirectional radio solution engineered to provide higher productivity through precise maneuvering. When you pair Jay with our RadioSafe Global Safety Stop, all machines can be halted with the push of a button, adding an additional safety layer in machine-to-machine communication.
Are you looking for a complete modernization overhaul?
Replace your existing system with our reliable, high-capacity Hevi-Bar II Conductor Bar system. Hevi-Bar II is low maintenance, easy to configure, installs fast, and has versatile mounting options. Hevi-Bar II is genuinely our "install it once and forget about it" conductor bar system.
Nexus BB is a brand new data over power solution for industrial applications, and works across many different conductor profiles including; festoon, cable chain, slip ring, conductor rail, and cable reels. Nexus BB creates a secured hardwired PLi-Fi (Power Line-Fidelity) connection through any conductor providing ultimate reliability. The secure signal travels through two of the power conductors, eliminating the need for additional signal conductors.
Nexus BB can be used on new and existing systems to add a secure data communication layer, and does not require any networking expertise or special equipment. Nexus BB replaces Wi-Fi with PLi-Fi for mobile equipment communication, with the same minimal maintenance as a WiFi solution. The innovative design adapts to noisy environments for dependable performance. Nexus BB is a plug and play solution that allows for easy modernization to existing installations with minimal downtime. Nexus BB is a data over power solution that provides a contained PLi-Fi signal for ultimate security through signal isolation.
Learn more about Nexus BB with our videos on YouTube
Material handling systems, automated overhead cranes, and other automated machinery often need an accurate way to determine the exact position of the moving machines or elements. You can use this information to assure correct vehicle spacing, provide material storage locations, or to give position feedback. The Conductix-Wampfler Optical Positioning System (OPS) offers a complete solution to supply the needed position information along a fixed rail. You can integrate our OPS into new installations or easily retrofit it onto existing applications.
The Optical Positioning System:
The Beta radio remote control operator module adapts to your application to make your process more efficient. This easy-to-use light-weight handheld module gives you incomparable freedom of movement, precise and agile quality maneuvers and higher productivity while ensuring your operators’ safety.
In grey ATEX version, it will even operate safely under permanent risk of explosion (gas: zone 0, dust: zone 20).
Fully compliant with safety and security standards:
ATEX manufacturer 2014/34/EU
EC type certificate issued by LCIE
Machinery directive 2006/42/EC:
EC type certificate issued by TÜV NORD
Radio and telecommunication terminal equipment:
(low voltage, electromagnetic compatibility, radio spectrum)
FCC part 15
Radio Equipment Directive (RED)
Frequency selection manual / automatic:
Technical Installation / User Manual
Installation / Technical Manual
The Global Safety Stop System for Radio Remote Controls focuses on SIL 3 – PLe wireless emergency stop to tackle critical dangers typically met in highly automatized factories / warehouses, robotized production cells, continuous process lines.
The front plate is removable for configuration.
Characteristics compliant with ETS 300 220
64 frequencies programmable in 433-434 MHz
1/4 wave, as accessory, plugs in to BNC connector
< -100 dBm
The Conductix-Wampfler Hevi-Bar II Conductor Bar System delivers the kind of reliable, high-capacity crane rail electric service needed by factories, mills, storage yards, people movers, and other rigorous applications.
Hevi-Bar II features:
Current Capacity Range:
500 amps, 700 amps, 1000 amps, and 1500 amps, at 600 volts.
Maximum Running Speed:
2,000 feet/minute (609.6 meters/minute)
DURA-COAT - For Corrosive Environments
Hevi-Bar II is available with our optional DURA-COAT finish. Dura-Coat is a specially formulated coating that combines a ceramic compound with an epoxy binder to provide superior corrosion resistance and adhesion to the base materials. The entire bar is coated except in the stainless steel collector shoe running area; the insulating cover is applied over the coating.
All metal parts of the collector arm are coated. Arms are not coated as they are made from high-strength glass filled polymer.
DURA-COAT is an ideal conductor bar for galvanizing and electro-plating lines, chemical plants, smelters, foundries and cast houses, coke and ore handling cranes, and oxidizing/electro-winning facilities.
Optimal corrosion protection even in tough environments. Flanges and reel drum are manufactured from hot dip galvanized steel.
Reliable operation with standardized slip ring assembly.
Highly durable, maintenance-free and contactless torque transmission - standard motor with magnetic coupler.
Travel speed: up to 100 m/min
Winding length: 200 m max
OD of spool:
- Random wind spool: 400 mm - 1,700 mm
- Monospiral spool or 3-2-3 spool: 1,100 mm - 3,600 mm
- Type W: 100 Nm - 400 Nm
- Type BNA: 300 Nm - 700 Nm
Slip ring assembly:
- Power max: 690 V – 200 A
- Control & Data max: 500V / 690 V - mA – 25 A
Temperature range: -20 °C - +60 °C