VAHLE Crane Technology
Individual solutions for heavy loads

Cranes are used in many industries. Steel producers, recycling yards and companies from the construction industry VAHLE offers reliable systems for energy and data transmission.

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VAHLE Intralogistics automated small parts warehouse
Automated conveyor technology in the internal flow of goods

Increasing production rates, high throughput volumes and short delivery times require partially or fully automated intralogistics.

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VAHLE Automotive Electric Monorail System (EMS)
Innovative solutions for flexible production processes

Adaptable manufacturing processes are the key to the greatest possible efficiency in vehicle production. VAHLE solutions for energy and data transmission make a significant contribution to this.

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VAHLE Port Technology
Innovative solutions for the ports of tomorrow

Zero emission is the requirement for the port of the future. With the solutions for energy and data transmission from VAHLE, port operators are getting closer to this goal.

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VAHLE Amusement Rides Ferris Wheel
Intelligent solutions for the rides of the future

The amusement, leisure and adventure sectors are often at the cutting-edge of the industry. That's why many ride builders and manufactures rely on VAHLE to provide roller coaster and ride passengers with increasingly extraordinary experiences. 

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VAHLE People Mover streetcar
Automated transport systems for the mobility of the future

Streetcars, sky trains or rolling sidewalks are the future of resource-saving mobility. Many manufacturers rely on components from VAHLE for the design.

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VAHLE General Industry
Innovative solutions for special mobile applications

Stadium roofs, waste incineration plants, facade elevators: Mobile industrial applications are used in many areas. VAHLE offers various special solutions for reliable energy supply and data communication.

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VAHLE data communication
Data communication: fast, flexible and secure

Advancing digitization requires the transmission of ever greater volumes of data. Our vCOM solutions ensure reliable data communication for the control of automated conveyor systems at all times.

Solutions for data communication
VAHLE positioning
Positioning: robust, flexible and precise

Modern manufacturing requires automated conveyor systems that can be positioned with extreme precision. The prerequisites for this are created by our robust vPOS solutions, which are available with both magnetic and optical processes.

Solutions for positioning
VAHLE control
Control: mobile, scalable and efficient

Automation is shaping modern production processes more than ever. Numerous mobile conveyor units must be reliably controlled. With our versatile vDRIVE solutions, this can be achieved flexibly and with optimized performance.

Solutions for control systems
VAHLE system solution
System solutions: Everything from a single source

With our holistic system solutions, we offer a perfectly coordinated product combination of power transmission, data communication, positioning and control for a wide range of applications.

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VAHLE Services
VAHLE offers a wide range of services and support, including installation and commissioning, maintenance and repair, spare parts management and training. We are also available to serve as a general contractor for your project, if required.
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Take a look behind the scenes of a family-owned company. In our career section, you can find out everything about everyday working life and job profiles at the VAHLE Group, our training and further education opportunities, and current vacancies. And don't be shy: We are always looking for new, motivated colleagues!

Smart Collector

Predictive Maintenance powered by VAHLE

Unplanned system failures often have unpleasant consequences. If the automated conveyor systems in modern production lines come to a standstill, nothing works anymore. The result is often a loss of sales, which can skyrocket to unimaginable heights if troubleshooting is time-consuming and tedious.

To solve this problem, VAHLE has developed the Smart Collector. The world's first intelligent current collector uses special sensor technology to record its linear and rotary movements and passes this data on to the Main Unit, where it is evaluated using the Intelligent Dynamic Anomaly Analysis (IDAA) method. In this way, the entire conductor rail system is monitored during operation.

For this purpose, the current collector arms of the Smart Collector are equipped with neodymium magnets. By measuring their magnetic fields without contact, the sensors register even the smallest changes in the flow of movement caused by wear of the conductor system. This allows anomalies to be detected at an early stage, maintenance cycles to be optimally scheduled and thus the availability and productivity of the entire plant to be significantly increased.

The Smart Collector was specially developed for electric monorail systems (EMS) and automated storage and retrieval systems (AS/RS), but can also be used in other types of plant. To this end, the smart system is compatible with various VAHLE conductor systems as well as data transmission and positioning solutions.

Your Vision. Our Solution.

Smart Collector

Product of the Year

Award-winning: Where energy and data flow, we set the standard for safety and efficiency. And we have the awards to prove it.

Smart Collector

Current collector with sensors

3D sensors on the current collector arms record the movements (stroke and deflection data) of the pantograph during operation. The function of the current collector is not influenced in any way. The data is transmitted to the Main Unit for analysis.

Smart Collector

Main Unit

The 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 flexible system has variable interfaces and is compatible with various positioning and data transmission systems.

Smart Collector

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.

Smart Collector


The analyzed measurement data is visualized by means of software and enables plant operators to perform ongoing condition monitoring as well as various service options, which can be accessed digitally using any terminal device.

  • Quick and easy implementation without structural changes (plug and play)
  • No intervention in the existing IT infrastructure
  • Detects lifting and deflection movements of the current collector arms
  • Positionally accurate determination of anomalies
  • Ongoing data analysis enables predictive maintenance
  • High compatibility with various VAHLE systems


Technical data - Electrical
Operating voltage 24 V
Max. current requirement 5 A
Max. data transfer rate 100 MBit
Protection class IP54
Technical data - Mechanical
Max. driving speed 300 m/min
Funnel operation possible
Technical data - system
Conductor 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
Use Indoor installations
  • Plant project planning and consulting
  • Installation and commissioning
  • Maintenance, repair and inspections
  • Modernization of existing plants (retrofit)
  • Multi-level training options

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