Smart Collector
The world’s first intelligent current collector
for electric monorail and automated storage and retrieval systems

Product of the Year 2023

Predictive Maintenance
powered by VAHLE

Since the invention of the copper conductor rail, VAHLE stood for technical progress. With the Smart Collector, we developed the world’s first intelligent current collector. Its sensors monitor the movement data of the current collector and, due to the IDA-Anaylse method, detect anomalies soon enough to avoid unplanned downtimes.

Our promise

With the learning system, which was specially developed for EMS and AS/RS systems, we strengthen our promise of quality.
The Smart Collector acts as an efficiency boost for your intralogistics processes.

  • Check Increasing productivity
  • Check Sustainable cost reduction
  • Check Reduction of reaction times
  • Check Minimization of downtimes
  • Check Increase in service quality
  • Check Reduction of storage costs
  • Check Planning reliability

The system in detail

Current collector with sensors

Current collector with sensors

3D sensors adapted to the current collector arms record the movements (stroke and deflection data) of the current collector during operation. The function of the current collector is not affected in any way. The data is transmitted to the main unit for analysis.

Main Unit

Main Unit

Measurement data is processed and evaluated using the Intelligent Dynamic Anomaly Analysis (IDAA) method. This is done in real time directly on the main unit. The system has variable interfaces and is compatible with various positioning and data transmission systems.

Data transmission

Data transmission

If the main unit detects reproducible anomalies, a message is transmitted to our certified data center via the data transmission (e.g. LTE or SMGM). A permanent transmission or storage does not take place.



The analyzed measurement data are visualized by means of VAHLE software solutions and enable plant operators to perform ongoing condition monitoring as well as various service options, which can be called up digitally using any terminal device.

Our software

  • Check Visualization of data and reporting of anomalies in the traffic light system
  • Check Unlimited data volume as well as data storage in the certified data center
  • Check Dashboard access from all devices

„Know today what will happen tomorrow. With the Smart Collector, VAHLE is giving the starting signal for the digitalization of the conductor system.“

Jessica Genz | Product Management, VAHLE Group

Early Bird

Take the chance and secure your Early Bird Smart Collector Bundle, consisting of hardware and software package at a special price. After the inspection run, you will receive a report on the condition of your plant and can avoid unplanned plant shutdowns today. You also benefit from our workshops and further information on future developments.


Plug & Play

  • Check No structural modifications necessary
  • Check Simple replacement of the existing current collector
  • Check Installation of the main unit and data transmission
  • Check Data transmission without affecting the IT infrastructure
  • Check Analysis software can be used on any terminal device
Ready for use within 2 hours
Analysis & evaluation

Analysis & evaluation

  • Check Analysis of stroke and deflections of the current collector
  • Check Measurement of carbon wear
  • Check Precise positioning detection of anomalies
  • Check Push notifications in case of anomalies from the TARGET values
  • Check Analysis reports for planning optimal maintenance

Advantages of the Smart collector

  1. 1 Easy implementation with Plug & Play
  2. 2 High compatibility with various systems
  3. 3 Simple installation in existing plants possible
  4. 4 Data analysis for predictive maintenance
  5. 5 Reduction of maintenance costs
  6. 6 Increasing process reliability
  7. 7 100% self-sufficient system solution

Market insights


of manufacturing companies are not fully aware of the condition of their plant.

Vanson Bourne global study


of time is spent on maintenance with predictive maintenance. With "reactive" maintenance, it is almost three times as much time.

Roland Berger


is the average cost of a one-hour machine downtime for manufacturing companies.

Aberdeen report


of maintenance costs can be saved through predictive maintenance. Unplanned downtime could be reduced by 70%.



of companies have had at least one and an average of two outages in the last three years.

Vanson Bourne global study

Make a consultation  appointment

Let us convince you of the advantages of the Smart Collector in an individual consultation.

What's next

The Smart Collector is being further developed so that it can also be used in other applications in the future. These include push skids, electric pallet conveyors, sorter or crane systems, and amusement rides. Our research and product management teams are already working on the latest sensor technologies that will make your installations safer, more predictable and more efficient. Stay up to date and don't miss any news. We'll be happy to keep you up to date on developments with our VAHLE newsletter.