Smart Collector

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 analysis 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:

Increasing productivity
Sustainable cost reduction
Optimization of response times
Minimization of unplanned downtimes
Increase in service quality
Reduction in storage costs
Planning reliability

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In detail

the system

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

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

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.

Software

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

Visualization of data and reporting of anomalies in the traffic light system
Unlimited data volume as well as data storage in a certified data center
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

Plug & Play

No structural modifications necessary
Simple replacement of the existing current collector
Installation of the main unit and data transmission
Data transmission without affecting with the IT infrastructure

Ready for use within 2 hours

Analysis & evaluation

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

Advantages of the Smart Collector

Easy implementation with plug & play
High compatibility with various systems
Simple installation in existing plants possible
Data analysis for predictive maintenance
Reduction of maintenance costs
Increasing process reliability

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

220

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 downtimes could be reduced by 70%.

Accenture

of companies have had at least one and an average 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.

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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.

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