Smart Collector

The world's first intelligent current collector
for electric monorail and automated storage and retrieval machines

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.



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
Jessica Genz

"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

  1. Easy implementation with plug & play
  2. High compatibility with various systems
  3. Simple installation in existing plants possible
  4. Data analysis for predictive maintenance
  5. Reduction of maintenance costs
  6. 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


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%.



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.

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.