Smart Collector

Intelligent Current Collector System for EMS & Stacker Cranes

Unplanned downtime in automated conveyor systems can quickly disrupt entire production or warehouse operations. When electric monorail systems (EMS) or storage and retrieval machines (SRMs) stop unexpectedly, troubleshooting and maintenance delays can lead to significant productivity losses.

The VAHLE Smart Collector is the world’s first intelligent current collector designed to monitor the condition of conductor rail systems during operation. By continuously analyzing the mechanical movement of the current collector, the system enables predictive maintenance and early detection of wear within the electrification infrastructure.

Using integrated sensor technology and VAHLE’s Intelligent Dynamic Anomaly Analysis (IDAA), the Smart Collector identifies irregular movement patterns that indicate developing faults in the conductor rail system. This allows maintenance teams to detect potential issues early, plan service intervals efficiently and significantly increase system availability.

The Smart Collector was developed primarily for electric monorail systems (EMS) and automated storage and retrieval machines (AS/RS), but can also be integrated into other conductor rail-based mobile systems. It is compatible with various VAHLE conductor rail systems as well as VAHLE positioning and data communication technologies.

Your Vision. Our Solution.

Smart Collector

Product of the Year

The Smart Collector has received multiple industry awards recognizing its contribution to predictive maintenance and intelligent infrastructure monitoring in automated industrial environments.

Smart Collector

Current Collector with Integrated Sensors

High-precision 3D sensors integrated into the pantograph arms measure lifting and deflection movements during operation. These measurements capture the dynamic interaction between the collector and conductor rail without affecting normal operation.

By detecting even minor deviations in movement patterns, the system can identify early signs of conductor rail wear or mechanical irregularities.

Smart Collector

Main Unit

Sensor data is processed directly within the Smart Collector main unit using the Intelligent Dynamic Anomaly Analysis (IDAA) method. The system evaluates measurement data in real time and identifies recurring anomalies that may indicate developing faults within the conductor rail infrastructure.

Flexible interfaces enable integration with various positioning and data communication systems.

Smart Collector

Data Transmission

If the main unit detects recurring anomalies, the system automatically transmits diagnostic information via available communication channels such as LTE or VAHLE’s SMGM data transmission system.

The system is designed to transmit only relevant data, so continuous data storage or permanent transmission is not required for operation.

Smart Collector

Monitoring Software

The collected and analyzed measurement data is visualized through an intuitive monitoring interface. Operators can track system condition, identify developing issues and plan maintenance activities proactively.

The platform enables continuous condition monitoring and provides digital service tools accessible from any connected device.

Plug-and-play installation without structural modifications
No integration required into existing IT infrastructure
Continuous monitoring of collector movement & conductor rail condition
Precise localization of developing anomalies
Predictive maintenance through ongoing data analysis
High compatibility with various VAHLE systems

Technical data - Electrical
Operating voltage	24 V
Max. current requirement	5 A
Max. Data transmission rate	100 MBit
Protection class	IP54
Technical data - Mechanical
Max. Travel speed	300 m/min
Hopper operation	possible
Technical data - System
Conductor rail systems	U10, VKS10
Current collector types	KDS 2/40, KUFR 2/40, KESR, KESL
Data access	Progressive Web App (PWA)
Max. installation time	90 minutes
Operating conditions
Operating temperature	-30°C to +55°C
Application	Indoor installations

System project planning and consulting
Installation and commissioning
Maintenance, repairs and inspections
Modernization of existing systems (retrofit)
Multi-level training options

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Smart Collector

Intelligent Current Collector System for EMS & Stacker Cranes

Product of the Year

Current Collector with Integrated Sensors

Main Unit

Data Transmission

Monitoring Software

Flyer Smart Collector

Betriebsanleitung Smart Collector

Operating Instruction Smart Collector

Flyer Smart Collector

Flyer Smart Collector

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