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MONTRACDesign Guide

1. ACCESSORIES FOR TRACDOOR Proximity switch M8 pluggable Connection cable 5 m with straight socket on one side Connection cable 10 m with straight socket on one side Base frame 1 for TracDoor Base frame 2 for TracDoor The opening direction is freely selectable 3000 Clear width 1850 981 983 TracDoor single L 2000 mm TracDoor single L 3000 mm mide MT56954 Part no MT508845 MT504610 MT507528 MT92064 MT92066 MONTRAC 83 BASE FRAME 1 FOR TRACDOOR 504 80 5 900 mm to top edge of Shuttle platform 767 Base frame 1 for TracDoor 2000 3000 with FW NINOS BASE FRAME 2 FOR TRACDOOR 900 mm to top edge of Shuttle platform re Base trame 2 for TracDoor 2000 with FW MT92066 84 MONTRAC TRACCONTROL 1 COMPONENTS TRACCONTROL 1 IRM The TC1 IRM Intelligent Routing Module is an optoelectronic communication module for data exchange allowing Shuttle Trac and master control to interact with each other The Shuttle and TC1 IRM communicate with each other via signals in the infrared spectrum The can function as a communication interface between the rail syste
2. du el Mounting set for PU 4 platform width 300 mm MT65394 80 MONTRAC BASE FRAME FOR POSITIONINGUNIT PU 4 PLATFORM WIDTH 200 MM Base frame for PU 4 platform width 200 mm MT65395 5E ari I Base frame for PU 4 platform width 300 mm MT65396 ri 165093 165094 165095 MONTRAC 81 TRACDOOR The TracDoor door allows passage through a Montrac line or access to manual work stations within the line It has its own base frames these have to be ordered separately It is intended to permit passage for at least one person or max a small forklift single and double version The principle of a TracDoor is very simple The gate is attached to a pivot point and can be opened manually When closing the gate is rotated to an end stop and can be locked manually TRACDOOR SPECIFICATIONS TracDoor length tolerance mm 22710 Material Aluminum nickel plated copper plastic Nominal voltage IV DC 24 Current carrying capacity between the Trac connections A 40 on the movable Trac section A 2 9 Ambiance Temperature 10 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance 82 MONTRAC TYPE OVERVIEW OF TRACDOOR SINGLE DOUBLE The opening direction and the pivot point position can be freely selected 2000
3. min 300 3 40 66 40 LP 66 40 x295 SLL 55 40 SLL 55 40 KW 40 AK 66 40 SLL 55 40 KW 40 SLL 55 40 TracSet Mounting Console MT57911 O N O O CN LIFT WALL MOUNTING max 500 min 230 40 66 40 511 55 40 LP 66 40 Ni QU meram kk LP 66 40 AK 66 40 SLL 55 40 KW 40 SLL 55 40 E Eos Wall Console MT57910 ST 700 260 180 260 EXTENSION OPTIONS FOR ANTI FALL GUARD AND STOP Lift X 9 5 115 MONTRAC 107 18 5 108 MONTRAC ACCESSORIES FOR LIFT Description R Connection Trac complete L Connection Trac complete Anti fall guard Box for anti fall guard Limit stop Trac with damper Basic with Y cable AB and A Cam A and AB Cam Set Motor line Return system line Return system line Supply cable wire number 7 for 24 V DC supply voltage servo control connection and external control 2 wire supply cable for Trac power supply Lift Control Set Control cabinet Control cabinet Keypad XT operating module min 1 per system PC USB system bus adapter if required Profibus bus module if required PC system bus adapter RS 232 if required Wall console TracSet mounting console Base framework for lift Options 5 meters 10 meters 20 meters 5 meters 10 meters 20
4. Part Platform length mm Positioning Lmin mm eT nd MT65092 300 single 580 Part no Platform length mm Positioning Lmin mm 400 single 840 MT65093 300 multiple 840 Part Platform length mm Positioning Lmin mm 550 single 1290 MT65094 400 multiple 1290 Part no Platform length mm Positioning Lmin mm MT65095 550 multiple 1500 MONTRAC 77 CYCLE TIMES IN SINGLE POSITIONINGUNIT SPU 4 10 290 480 520 F amp 30 87C0 Running direction o o Bomm 120mm CYCLE TIME SINGLE POSITIONINGUNIT SPU 4 desme Si sine 3 Twin Axle Shuttle with Shuffle Twin Axle Shuttle with with maximum load with maximum load 8 load is load S S Platform L 300 mm 2 90 2 80 Platform L 400 mm 2 200 Platform L 550 mm 3 34 255 3 20 3 20 Time measurement From the start command of the control element IRM in the PU to the presence signal of the control element IRM in the PU The rear Shuttle was positioned relative to the front Shuttle via the distance sensor distance 100 mm Following configuration of the cams was used Entrance speed 30 m min allowed only in protected area distance AB to A Cam 130 mm length 45 mm At an entrance speed of 12 m min the cycle time in the SPU is extended by two seconds 78 MONTRAC Running direction CYCLE TIME FOR INCREMENT b IN MULTIPLE POSITIONINGUNIT MP
5. 4 1004 1 2 P eo LO 3 on hn ME 08 01 o LN ozi 666 utu 098 2 606 190415 1 1 J914J 2 gt p Or 08 666 068 1 2211 JO 1 Stroke in example diagram 1000 mm Part no Shuttle platform top edge 900 mm MT56976 Lift Please state lower position and maximum stroke when placing order LIFT CONTROL SET MT58562 SPECIFICATIONS SERVO POSITIONER 9300 type EVS9322 EP Nominal voltage Nominal current with mains filter Auxiliary voltage supply Type of protection Installation type Weight BRAKE UNIT 9350 type EMB9352 E Supply voltage Peak current for 60 s Max continuous current Type of protection Installation type Weight MAINS FILTER type EZN3A1500H003 Rated voltage Peak current for 60 s Max continuous current Type of protection Installation type Weight Ambiance Temperature Rel air humidity Air purity level A kg A DC A DC kg A DC DC kg MONTRAC 103 3x 380 480 V 50 Hz 60 Hz 2 9 24 V DC 096 15 909 5A IP 20 Vertical control cabinet 3 9 270 775 42 25 12520 Vertical control cabinet 222 500 42 25 10 Vertical control cabinet 10 t
6. Basic with Y cable AB and A Cam TCI Basic Kit TC1 IRM MT56937 Box Single supply cable TC1 Curve Kit TC1 IRM holder for signal generator Box single MT56938 supply cable TC1 Double Module Kit TC1 IRM holder for signal generator Box double MT56939 supply cable TC1 Double Sensor Kit TC1 IRM 2 x holder for signal generator Box MT56940 double supply cable 86 MONTRAC TRACCONTROL ACCESSORIES Part no Proximity switch M4 with cable and connector 58 MT520292 Proximity switch M8 PnP pluggable MT508845 Proximity switch holder MT45428 A Cam straight MT47200 A Cam complete L 21 44 mm MT90730 21 44 B Cam 145314 45315 A and AB Cam Set MT90759 Flag AB and A Cam MT57020 Flag for AB cam MT58183 Flag for B cam MT58184 Flag A Cam for PU 4 MT57008 Flag A Cam for PU 4 CCW MT57442 Electrically switchable cam oft power off for Shuttle visible MT57023 Electrically switchable cam on power off for Shuttle invisible MT57024 Assembling gauge for IRM 192008 ShuttleLock MT56925 ACCESSORIES FOR TRACCONTROL 1 IRM Part no TC1 IRM cabling L 1500 mm MT56986 Cable for TC1 IRM Box supply MT57184 PC connection cable MT57579 Connection cable 5 m with straight socket on one side MT504610 Connection cable 5 m with angled socket on one side MT504929 Connection cable 10 m with straight socket on one side MT507528 Connection cable 10 m with angled socket on one side
7. steps More information to this can be found on O pages 24 to 114 S L A cost free O configurator software is available for the planning and 7 configuration of a Montrac system Complete production lines can be easily configured with drag and drop commands and a 3D visualization with an appropriate bill of materials is available immediately More information to this can be found on pages 16 to 17 T 2 HEN 4 23 17 v PA 60 e or Hast S f TracSet is a universal modular system for superstructures and base frames of the Montrac system It offers a variety of possibilities The profile system allows quick and easy installation without mechanical processing More information to this can be found on pages 115 to 124 and 5994995 gt The TracControl 2 drive control of the ON Montrac system can be designed according to Xo individual requirements and provides flexible solutions for simple transport tracks up to complex production processes with interfaces to external controls or higher level control systems More information to this can be found on pages 18 to 23 and 84 to 99 a omo E p r THE MONTRAC SYSTEM COMPONENTS Montrac stands for absolute flexibility in conveyor technology and thus for practical
8. be downloaded from the website www schmid group com MONTRAC 9 ACCESSORIES FOR TRACCONTROL 1 IRM BOX DOUBLE DIMENSION DRAWINC The Box double is used for wiring a Montrac system The Box double is the interface between one or two TC1 IRMs and their peripherals or master control Since all the inputs and outputs of the TC1 IRM can be picked up in the box it is universally usable 18 2 48 0 87 5 58 89 9 Ll vi Box Double MT56985 TRACCONTROL 1 IRM ACCESSORIES SPECIFICATIONS BOX DOUBLE MT56985 Net weight 0 220 Max cable cross section mm 0 5 Max cable diameter mm 2 Max voltage IV DC 24 Max current A 2 Ambiance Temperature C 10 to 40 Rel air humidity 5 85 96 without condensation Air purity level normal workshop ambiance ACCESSORIES FOR BOX DOUBLE MT56985 Part no Cable tor TC1 IRM Box supply MT57184 PC connection cable MT57579 With the PC interconnection cable MT57579 and by means of a Shuttle the TC1 IRM can be configured using the box The latest version of the TC1 IRM ISM software be downloaded from the website www schmid group com 92 MONTRAC ACCESSORIES FOR TRACCONTROL 1 IRM CONFIGURATOR UNIT MT56944 DIMENSION DRAWING The configuration unit serves to configure the TC1 IRM Intelligent Routing Modules With the aid of software TC1 IRM TC1 ISM Configurator the desired functions can be assigned to an TC1 IRM and the neces
9. 12 MONTRAC TRACCURVE In the Montrac transport system changes of Trac direction by 45 or 90 are realized by curved Tracs The minimum connection radius of 220 mm gives Montrac unparalleled flexibility TRACCROSSING The crossing makes it possible for two lanes to intersect each other at a right angle The electrical power is supplied directly from the conductor rails TRACSWITCH The TracSwitch is used to distribute Shuttles from one lane to two and vice versa Thanks to the narrow radii bypasses and branches are realized in a confined space The TracSwitch is operated electrically and is powered directly from the conductor rails LIFT The lift is used for the vertical transport of Shuttles to solve the following tasks connecting two or more systems with different working heights and feeding of Shuttles from a station to a ceiling system or vice versa TRACSWITCH ARENA The TracSwitch Arena serves to convey the Shuttles either from one lane to a bypass 45 output or to the main lane Thus it is possible to perform a complete bypass with a single component WORKPIECE PLATFORMS The workpiece platforms are the link between the products and the Shuttle The platforms are available in various sizes The number and location of the positioning prisms is a customer specific choice The prisms serve as counterpart of the PositioningUnit locking points MONTRAC 13 SUPOTRAC
10. Delivery options The TracSwitch Arena can be ordered mounted and ready configured according to the desired switch type at montratec With the unconfigured TracSwitch Arena the customer can assemble the conductor rails according to his application and can configure the TracSwitch Arena himself The TracSwitch Configurator can be downloaded from the website www schmid group com TRACSWITCH ARENA SPECIFICATIONS Net weight kg 959 Material Aluminum nickel plated copper steel brass plastic Nominal voltage IV DC 24 Connections 1 852922 3 x DIN per position used 1 x DIN 4 x DOT per position used 1 x DOT 1 x Error Rotation angle 27 22 Rotation time 60 150 210 sec 60 0 5s 150 1s 210 1 5s Torque of the rotary plate Nm 20 Current carrying capacity between the Trac connections A 40 on movable Trac section A 2 9 Mechanical load capacity N 340 Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility TracLink MT57949 corresponds to the weight of a fully loaded Twin Axle Shuttle MONTRAC 55 TRACSWITCH ARENA DIMENSIONS Free space Free space 150 mm 150 mm 465 3 537 3 _ TracSwitch Arena MT58879 ACCESSORIES FOR TRACSWITCH ARENA Part no Configuration by montratec MT56935 PC connec
11. AK 96 40 MONTRAC 149 Lid of ABS plastic to close off the TP support profiles COVER CAP AK 16 40 AK 66 40 AK 96 40 gray Part no for AK 16 40 for TP 16 40 48619 Part no for AK 66 40 for 66 40 or 66 40 MT61163 Part no for AK 96 40 for TP 96 40 48618 blue MT61113 150 MONTRAC CLAMPING ELEMENT LONGITUDINAL LONGITUDINAL SLL 55 40 in clamped state For connection of dovetail profiles under high load For connection of dovetail profiles in clamped state under medium load CLAMPING ELEMENTS SPECIFICATIONS CLAMPING ELEMENT CLAMPING ELEMENT LONGITUD LONGITUD SLL 55 40 LONGITUD LONGITUD SLL 20 40 Resistance to misalignment of two joining profiles 3000 1350 Torque value of screw s Nm 6 6 Parallelism of clamped surfaces mm 0 02 0 02 Weight kg 0 055 0 020 Part no MT65470 MT65464 MONTRAC 151 CLAMPING ELEMENT LONGITUDINAL LONGITUDINAL SLL 12 40 For connection of dovetail profiles in clamped state under low load CLAMPING ELEMENT LONGITUD LONGITUD SLL 55 22 40 For the connection of dovetail profiles under high load and in clamped state increased clearance CLAMPING ELEMENTS SPECIFICATIONS CLAMPING ELEMENT CLAMPING ELEMENT LONGITUD LONGITUD 50 12 40 LONGITUD LONGITUD SLL 5 22 40 Resistance to misalignment of two joining profiles N 750 3000 Torque value of screw s Nm 6 6 Parallelism of clamped
12. Air purity level normal workshop ambiance Max load without Shuttle incl platform kg Shuttle with length L 300 mm 1522 Shuttle with length L 400 mm 12 68 MONTRAC ERGOTRAC DIMENSIONS Platform size mm L ErgoTrac with ShuttleLock for platform width 200 mm and 300 m MT56952 ACCESSORIES FOR ERGOTRAC Part no Single leg support MT56817 Support for ErgoTrac MT58594 Base for TracLink tabletop 57431 Base frame for Trac tabletop MT54819 Cylinder switch PNP pluggable for cylinder 506885 Connection cable 5 m with straight socket on one side MT504610 Connection cable 5 m with angled socket on one side MT504929 Connection cable 10 m with straight socket on one side MT507528 Connection cable 10 m with angled socket on one side MT507529 Proximity switch M4 with cable and 15220222 connector 58 for ShuttleLock MONTRAC 69 HOLDING MOMENTS OF THE TILTING MOVEMENT AT 5 BAR Shuttle platform Shuttle SupoTrac The holding moments may be utilized only when the Shuttle platform is appropriately supported HOLDING MOMENTS Holding moments In horizontal position In inclined position T MHX 13 Nm 13 Nm MHX 13 Nm 10 Nm TILTING TIMES Throttle position on Tilting time Throttle position drive cylinder Direction of movement Shuttle load s on piston rod side on piston bottom side Empty 1 1 Open by 1 revolution inclin
13. Increasing productivity thanks to flexible and intelligent intralogistics 12 2013 issue in English 2 MONTRAC montratec the montratec logo Montrac and the Montrac logo are trademarks or registered trademarks and are property of montratec AG Switzerland All other brand names trademarks and registered trademarks are property of their respective owners and are recognized All data is for informational purposes only is subject to change and is not guaranteed for legal purposes Information in this document has been carefully checked and is believed to be accurate However no responsibility is assumed for inaccuracies Copyright 2013 montratec AG Switzerland All rights reserved MONTRAC 3 MONTRATEC REFERENCES Boehringer Ingelheim _ E ESCHENBACH REEMTSMA Z RADINE 4 VIMAR Energia positiva KIRBY saia burgess Boehringer Ingelheim IV Pharmaton blicina 4 MONTRAC MONTRAC IN USE Antistatic and low power consumption Efficient and fully automated intralogistics Intralogistics for unattended clean rooms 1 Flexibility for the Future With montratec s technology we could customize the transport system according to our production needs eliminating dust reducing consumption and optimizing the entire production cycle Vincenzo Lioy Managing Director Triom Wit
14. The Supolrac serves as a support for manual workstations In the the workpiece platform is slightly raised from the Shuttle Thus processing is possible without having to strain the Shuttle with forces the forces are transmitted to the Trac TRACCONTROL COMPONENTS The TracControl components are used to control the route and the Shuttles of a Montrac system ERGOTRAC With the ErgoTrac a manual workstation can be set up more ergonomically The workpiece platform is tilted 25 towards the operator This makes the platform ergonomically more easily accessible and improves the visibility TRACSET The profile system convinces through cross product compatibility and flexibility The proven dovetail system allows a quick and easy assembly of all Montrac products POSITIONINGUNIT 4 A PositioningUnit is used when the Shuttle is to be precisely positioned and or when the workpiece platform must be additionally supported during the machining operation The PositioningUnit is available for single and multiple positioning 14 MONTRAC PROFITABILITY EFFICIENCY 300000 The latest development stage of the Euro Montrac system is particularly aimed at increasing its efficiency T 250000 The power for various components is directly supplied through the conductor rail so very little cabling is required With the Chaos Technology the control effort is reduced or totally eliminated L
15. cm cm mm m mm m kg m 1480 23 25 76 76 according to DIN 7168 medium 1 0 7 5226 42852 3000 143 144 MONTRAC SUPPORT PROFILE TP 96 40 Precision aluminum rod extruded profile acc to DIN 17615 hardened warm anodized natural end face cut nearly burr free SUPPORT PROFILE TP 96 44 SPECIFICATIONS Profile surface mm 17157 Section modulus Wx 27 82 Wy cm 27 02 Moment of inertia Jx 191 58 Jy lels Length tolerance according to DIN 7168 medium Torsion tolerance mm m Straightness tolerance mm m 0 7 Weight kg m 4 771 Part no for length 3000 mm 143207 3000 LOAD DIAGRAM N 30000 10000 7000 5000 3000 2000 1500 1000 700 500 300 200 100 70 50 30 20 10 5 3 172 0 2 0 3 0 40 9 Q MONTRAC 145 4 16 40 16 40 48 9 LP 66 40 K 666 TP 66 40 1302 96 40 3146 Example Given 66 40 1 1 5 m Result Fmax 738 Example 2 Given TP 16 40 90 Result Lace 0 4 in Example 3 Given im P 500 N Result LP 66 40 Profile 146 MONTRAC ADAPTER PROFILE AP 40 40 ADAPTER PROFILE SPECIFICATIONS Profile surface Section modulus Wx Wy Moment of inertia Jx Jy Length tolerance Straig
16. 5 BASE FRAME FOR TRACCURVE 907 R520 926 7 885 525 900 mm to top edge of Shuttle platform TS base frame for TracCurve 90 8520 MT58580 525 900 mm to top edge of Shuttle platform TS base frame for TracCurve 45 R520 MT58589 124 MONTRAC 5 BASE FRAME FOR TRACCURVE 1807 R520 727 735 _ 112 10012021 1 1 mw Fw y p WwW 900 mm to top edge of Shuttle platform 1340 TS for TracCurve 180 8520 MT58642 ACCESSORIES FOR TRACSET BASE FRAMES Part no Segment anchor M 12x 80 5 MT507557 Cable duct KFM 40 L22000 mm MT45229N2000 Cable duct KFM 40 0025 mm MT45229N0025 MONTRAC 125 SPECIAL COMPONENTS Customer specific special components are listed further down The development engineers of the montratec AG are pleased to offer support and guidance in the implementation of special solutions The contact details are shown on the back of this catalog SHUTTLE MSHI 4 INDUCTIVE Owing to their special shape the Shuttles are self centered on the monorail Driven by a maintenance free low voltage electric motor that is E fed by an inductive non contact energy transmission they reach a speed of 30 m min Each Shuttle has its own contr
17. MT61613 MX TC2 IRM CAN with cable CAN Y distributor A and AB Cam MT61614 MX TC2 IRM CURVE with cable to sensor and AB Cam MT61615 TRACCONTROL 2 WIRING Part no TracSwitch cable M12 8 pin 1 5 m MT521121 TracSwitch cable M12 8 pin 3 m MT521122 TracSwitch cable M12 8 pin 5 m MT521123 TracSwitch cable M12 8 pin 10 MT521124 Sensor cable M8 3 pin 1 5 m MT521117 Sensor cable M8 3 pin m MT521118 Sensor cable M8 3 pin 5 m MT521119 Sensor cable M8 3 pin 10 m MT521120 CAN cable M12 1 m MT521125 CAN cable 12 2 MT521126 CAN cable M12 5 m 521127 CAN cable M12 10 MT521128 Detect Start cable TC2 IRM MT61470 TC2 IRM supply cable MT61446 Cable to TC2 IRM sensor MT61444 Cable CAN TC2 IRM MT65262 Cable to TC2 IRM consumer MT61612 Y Vert 5 M12 ST to 2 x M12 socket 000010484 000 100 MONTRAC LIFT The lift allows the vertical transport of the Shuttles Use the following tasks as examples Connecting two or more systems of different work heights Taking Shuttles from a station to a ceiling system or vice versa Protection of employees in the lift area is imperative LIFT SPECIFICATIONS Net weight basic construction kg 75 per additional meter kg 14 Min clearance between the Trac and the floor mm 595 Max stroke mm 2 Max additional load kg 34 Max speed m s 25 acceleration with 17 kg load m s 5 Max acceleration
18. TE ici E 19 mm Weight kg 0 050 MT65502 Part no 90 angle connector for low load 90 angle connector for medium lt load CORNER CONNECTOR EV 3 40 PACK OF 4 3000 6 0 03 related to a length of 45 mm Ch si MT65469 pack of 4 pre assembled and packed CORNER CONNECTOR EV 4 40 PACK OF 4 CORNER CONNECTOR SPECIFICATIONS Resistance to misalignment Fastening torque of screws Perpendicularity of clamping grooves related to a length of 70 mm Weight Part no IN Nm mm kg in clamped state CORNER CONNECTOR EV 4 40 PACK OF 4 4500 6 0 04 related to a length of 70 mm 05750 MT6547 pack of 4 pre assembled and packed MONTRAC 155 90 angle connector for high load 90 angle connector for medium load with cable duct CORNER CONNECTOR EVD 4 40 3000 6 0 04 related to a length of 45 mm 0 200 MT65472 156 MONTRAC CLAMPING PROFILE SP 64D 40 Adapter with double row hole pattern CLAMPING PROFILE SPECIFICATIONS Weight kg 0 040 Part no MT41133N FRONT SIDE ADAPTER STA 40 Dovetail profile for attachment on the face FRONT END ADAPTER SPECIFICATIONS Mx perm Nm 50 My perm Nm 50 Mz perm not admissible Fz 900 Fastening torque of screw Nm 6 Weight kg 0 280 Pan no WMS 77 MONTRAC 157 BASE ANGLE BW 40 A 4 0 05
19. The grounding conductor is led with the supply line from the switching cabinet to the plant The connection to the system is made by using the grounding element ERE 40 x GROUNDING CONTACT ELEMENT By mounting the grounding contact elements a conducting connection via the TracSet clamping elements is generated 114 MONTRAC GROUNDING CONTACT ELEMENT SPECIFICATIONS CONTACT ELEMENT CONTACT ELEMENT CONTACT ELEMENT GROUNDING 7 8 GROUNDING 7 GROUNDING 22 Use If electric cables with voltages gt 50 V AC or 75 V DC are laid 82 directly on TracSet profiles the B profiles must be grounded 92 OT 4 2 40 EV 3 40 EV 4 40 000 51200240 9 ping KV 40 SLR 15 40 Weight kg 0 010 0 010 0 013 Part no MT55105 MT65992 MT65991 GROUNDING ELEMENT ERE 40 _ Z oe ELI AN Example of Use Example of use By screwing in the grub screw into the corner connections the isolating anodized coating is destroyed at the connection points This ensures an electrically conductive connection between the individual aluminum profiles of the base frame The eye of the ground cable is fixed with the hexagon nut on the projecting thread shaft GROUNDING ELEMENT SPECIFICATIONS GROUNDING ELEMENT ERE 40 Use It electric cables with voltages gt 50 V AC or 75 V DC are laid directly on TracSet profiles
20. rubber PC 10 to 40 5 96 85 96 without condensation normal workshop ambiance V DC 24 V DC 19 36 A 5 4 W 129 2 V DC 24 26 02 4 2 IW 100 8 mVpp 150 Aluminum copper steel brass plastic F no condensation Natural air cooling 10 to 40 5 96 85 96 without condensation normal workshop ambiance 112 MONTRAC ISOLATIONTRAC DIMENSIONS IsolationTrac 300 MT56945 115 IsolationTrac 660 MT56946 including DC DC converter DC DC converter MT506859 190 20 660 20 131 113 MONTRAC PLANT GROUNDING CONCEPT The rail system of the Montrac transport system is mounted on individual TracSet base frames Contrary to conventionally manufactured welded steel frameworks these aluminum profile constructions are not generally joined together with electrically conductive connections TracSet supplies in its product range grounding elements by which a permanent electrically conducting connection among the individual components can be created Thus additionally attached components such as grounding strips are not necessary which has a positive impact for the appearance of the whole plant TRACLINK TRANSITION GROUNDING CONNECTION The Trac sections are mechanically connected via the clamping bracket of the TracLink In addition the entire rail system is grounded by screwing in the grub screws into the clamping bracket
21. the profiles must be grounded The conversion kit applies to the following clamping elements Weight kg 0 030 Part no MT54960N TRACSET BASE FRAMES Appropriate base frames are available for all Montrac components The base frames have a modular design such as the rail system If necessary the height of the base frames can be adapted to customers wishes TRACSET BASE FRAMES SPECIFICATIONS Material Ambiance Temperature C Rel air humidity Air purity level MONTRAC Aluminum nickel plated copper steel brass plastic 10 to 40 5 96 85 96 without condensation normal workshop ambiance HS 116 TS BASE FRAME FOR 90 EL MES TS base frame for Trac tabletop MT54819 5 BASE FRAME FOR TRACLINK TABLETOP OO O TS base frame for TracLink tabletop MT57431 MONTRAC 117 SINGLE LEG SUPPORT FOR TRAC 652 80 5 rt no of Shuttle platform Single leg support for Trac MT91565 SINGLE LEG SUPPORT FOR TRACLINK rt no of Shuttle platform Single leg support for TracLink MT56817 118 MONTRAC DOUBLE LEG SUPPORT FOR TRAC TRAC N 652 80 5 900 mm to top edge of Shuttle platform Ts Double leg support for Trac Trac MT91569 DOUBLE LEG SUPPORT FOR TRACLINK TRACLINK 900 mm to top edge of Shuttle platform Lum Double leg suppor
22. 142 Swivel caster for light profile Fixed casters each with corresponding adapter CASTER SPECIFICATIONS SWIVEL CASTER LRTP 75 40 FOR SWIVEL CASTER LRTP 75 40 FOR SUPPORT PROFILE 1 66 20 LIGHT PROFILE TP 66 40 Max load in axial direction N 580 580 Weight kg 0 465 506 Part no MT54267 MT54269 164 MONTRAC FIXED CASTER BRTP 75 40 5 40 Fixed caster for support profile Fixed caster for light profile FIXED CASTER SPECIFICATIONS Max load in axial direction Weight Part no 122 142 122 142 Fixed casters each with corresponding adapter kg FIXED CASTER 5 40 FORSUPPORT PROFILE TP 66 40 580 227 MT54268 FIXED CASTER BRLP 75 40 FOR LIGHT PROFILE LP 66 40 580 0 420 MT54270 MONTRAC 165 FOUNDATION ANCHOR BRACKET FW 40 For floor attachments and connections with constructions incompatible with TracSet made of cast aluminum FOUNDATION ANCHOR BRACKET SPECIFICATIONS Perpendicularity between base surface and mm 0 Dovetail in relation to the flank length 49 mm Weight kg 0 440 Part no 46201 GET ON THE RIGHT TRAC MONTRAC SCHMID Group montratec AG Zielmattenring 6 4563 Gerlatingen Switzerland Phone Phone 41 32 55 88 700 Fax 41 32 55 88 799 info montrac Qschmid group com www schmid group com
23. 70 mm each time 60 MONTRAC TRACCROSSING The TracCrossing makes it possible for two lanes to intersect each other at a right angle The electrical power is supplied directly from the conductor rails Delivery options The TracCrossing can be ordered at montratec mounted and configured The configuration of the unconfigured TracCrossing can be done by the customer himself The TracCrossing Configurator can be downloaded from the website www schmid group com TRACCROSSING SPECIFICATIONS Net weight kg 12 Material Aluminum nickel plated copper steel brass plastic Nominal voltage IV DC 24 Connections x R5292 2 x DIN per position used 1 x DIN 3 x DOT per position used 1 x DOT 1 x Error Rotation angle 90 Rotation time 90 sec 1 4 Torque of the rotary plate Nm 20 Current carrying capacity between the Trac connections A 40 on the movable Trac section A 2 9 Mechanical load capacity N 340 Ambiance Temperature C 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility TracLink MT57949 corresponds to the weight of a fully loaded Twin Axle Shuttle MONTRAC 61 TRACCROSSING DIMENSIONS Free space Free space 150 mm 150 mm ACCESSORIES FOR TRACCROSSING Part no Configuration by montratec 56935 PC connection cable MT
24. Multiple cable duct Fixed screen profile 22 Covering Covering cap Abbreviation TP 16 40 LP 66 40 TP 66 40 TP 96 44 AP 40 40 AP 56 40 KFM 40 FFP 40 AK 16 40 AK 66 40 Part no MT44207N2000 MT49260N3000 142852 3000 143207 3000 141258 2000 146253 2000 145229 2000 145159 2000 Gray 148619 Gray 1163 Blue MT61113 Page 141 142 143 144 146 146 147 148 149 149 TRACSET COMPONENTS OVERVIEW Figure Description Covering cap Clamping element longitudinal longitudinal Clamping element longitudinal longitudinal Clamping element longitudinal longitudinal Clamping element longitudinal longitudinal Clamping element longitudinal longitudinal Clamping element longitudinal round Cross connector Corner connection Corner connection Abbreviation AK 96 40 511 55 40 51 20 40 50 12 40 SLL 55 22 40 SLL 20 22 40 SLR 15 40 KV 40 EV 3 45 40 EV 2 40 MONTRAC Part no Gray 48618 MT65470 65464 165465 165466 MT65467 MT65475 MT65474 MT65473 165502 157 Page 149 150 150 19 151 152 152 153 153 154 138 MONTRAC TRACSET COMPONENTS OVERVIEW Figure Description Corner connection Corner connection Corner connection Clamping profile Front side adapter Base angle 90 angle bracket Adjusti
25. The versatile properties of Montrac allow a flexible connection of individual production steps up to a systematic process interlinking and complete automation of entire production lines ADVANTAGES OF MONTRAC RELIABILITY No production process should be unnecessarily blocked or even come to a standstill All components of the Montrac system are extremely low maintenance and durable Thus Montrac is a very reliable transport system and prevents blockages and system failure thanks to its innovative technology If nevertheless a defect should occur on a Shuttle material handling vehicle it can be removed fast and replaced in a single move without stopping the line SIMPLICITY Montrac was designed to be extraordinarily simple Thanks to the compact and standardized components of the monorail system planning and design are very simple and very space efficient Thanks to the intelligent control the smart Montrac Shuttles material handling vehicles can find the transport destination on the monorail system independently FLEXIBILITY Production processes are subject to constant change and continue to develop At any time Montrac can quickly be adapted to new circumstances All components have the same basis and are compatible with each other Montrac can perfectly adapt to spatial conditions The layout design possibilities are endless Depending on the situation or need the transport track can also be mounted at the ceiling to keep the area f
26. etc through the OPC protocol Interface for communication with TC2U based on UDP MONTRAC 97 DISPLAY AND OPERATING FUNCTIONS OF THE TC2 MFCs 111111 The positions and travel destinations of the individual Shuttles are displayed Advantages visualization and clearly laid out display of the material flow of the whole system 2 2 T o 8 lt lt gt lt HE 7 2 ACCESSORIES The statuses of the Montrac Error messages are displayed and components such as TracSwitch lifts can be reset etc are displayed and can be Advantage enables remote changed diagnostics and support Advantage system status is intuitively apparent Various system specific data are displayed and logged Advantages a Material tracking Error reproduction Shuttle material and status report Part no PC 19 industrial acc to Spec Win EA 000001666 000 USV Back ups CS650 USB BK650E EG 0000001 12 000 Angle bracket V2A computer fixture CPU SWIT RE 16 012 0169 0001 17 touch screen monitor serial USB PC extender Lindy junior set 3 in 1 KVM cable 5 2 St St 2m SUB D extension Bu St 9 pin 1 8 Holder AIMg3 0100X0150X2 EA 00000101 4
27. nearly burr free SUPPORT PROFILE TP 16 40 SPECIFICATIONS Profile surface Section modulus Wx Wy Moment of inertia Jx Jy Length tolerance Torsion tolerance Straightness tolerance Weight Part no for length 2000 mm mm cm cm cm cm mm m mm m kg m 368 1 025 1 640 0 820 3 280 according to DIN 7168 medium 1 0 7 0 980 44207 2000 142 MONTRAC LIGHT PROFILE LP 66 40 ZN Precision aluminum rod extruded profile acc to DIN 17615 hardened warm anodized natural end face cut nearly burr free Most suitable for base frames and superstructures which are not dynamically loaded LIGHT PROFILE LP 66 40 SPECIFICATIONS Profile surface Section modulus Wx Wy Moment of inertia Jx Jy Length tolerance Torsion tolerance Straightness tolerance Weight Part no for length 3000 mm mm cm cm cm cm mm m mm m kg m 809 13 18 45 45 according to DIN 7168 medium 1 0 7 2 186 49260 3000 SUPPORT PROFILE TP 66 40 Precision aluminum rod extruded profile acc to DIN 17615 hardened warm MONTRAC anodized natural end face cut nearly burr free SUPPORT PROFILE TP 96 44 SPECIFICATIONS Profile surface Section modulus Wx Wy Moment of inertia Jx Jy Length tolerance Torsion tolerance Straightness tolerance Weight Part no for length 3000 mm mm cm cm
28. of montratec AG PRINCIPLE Technical information Hall drawing Ancillary conditions dimensions LAYOUT Track components Base frames and Shuttle Drive control components QUOTATION Transmission of the PX file to montratec Quotation for transport system MONTRAC 17 LINKING OF INFORMATION The Montrac Configurator offers the possibility to import drawings and floor layouts and thus to plan customized Montrac systems to millimeter accuracy With simple means 3D contours and surface elements can be added as well in order to reliably include interfering contours After completion of the planning the layout can be exported for example as a 3D DWG By import into a CAD program a complete 3D model that is accurate in every detail can be generated from this very quickly AUTOMATED PROCESS STEPS The user friendliness of the Montrac Configurator is characterized by the fact that several process steps are automated Thus for example all control elements required to control the route can be added with one mouse click In addition an open routing can be closed with just one click after selection of the connection components This considerably simplifies and accelerates the creation of a layout and also ensures that only the components actually required appear in the list 50 without any programming skills the control and or control elements required can be configured LIBRARY Various basic configurat
29. of the TracSet please refer to chapter TracSet starting on page 133 38 MONTRAC TRACLINK The TracLink is the connecting element between two Trac sections or active components e g TracSwitch This element provides the electrical connection for the conductor rails and allows for thermal dilatation The power supply to the system is also performed by TracLink With the built in connection the GND conductor rail is connected to the potential of the TracLink aluminum body TRACLINK SPECIFICATIONS Net weight kg 722 Material Aluminum copper steel brass plastic Nominal voltage IV DC 24 Current carrying capacity A 64 Ambiance Temperature TONS Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility Trac MT56926 XXXX MONTRAC 39 TRACLINK AND POWER SUPPLY CABLE DIMENSIONS 39 5 40 For power supply optional with cable MT57949 and cable mounting ACCESSORIES FOR TRACLINK Part no Power cable 10 m MTS7577 Power cable 30 m Base frame for TracLink tabletop MT57431 for TracLink Single leg support MT56817 for TracLink TracLink Double leg support MT58298 for TracLink Trac Double leg support MT58299 for TracLink 3 leg support MT57948 40 MONTRAC TRACEND DIMENSIONS end piece with open routing Part no MT56788 TracEnd MONTRAC 41 TRACCURVE I
30. surfaces mm 0 02 0 02 Weight kg 0 016 0 096 Part no MT65465 MT65466 152 CLAMPING ELEMENT LONGITUDINAL LONGITUDINAL SLL 20 22 40 in clamped state CLAMPING ELEMENT SPECIFICATIONS CLAMPING ELEMENT LONGITUD LONGITUD SLL 20 22 40 Resistance to misalignment of two joining profiles 1350 Torsional strength Nm Torque value of screw s Nm 6 of clamped surfaces Parallelism mm 002 Weight kg 0 022 Pan no MT65467 For the connection of outer dovetail profiles under medium load and increased clearance Connector between truncated cone and dovetail CLAMPING ELEMENT LONGITUDINAL ROUND SLR 15 40 3000 90 6 of the support surfaces ae 10 05 0 070 65475 MONTRAC 153 CROSS CONNECTOR KV 40 in clamped state For connection of two dovetails intersecting at right angles in clamped state 45 angle connector CORNER CONNECTORS AND CROSS CONNECTORS SPECIFICATIONS CRO SKA ONNE MO KV 40 EV 3 45 40 Resistance to misalignment N 1500 3000 Fastening torque of screw s Nm 6 6 Weight kg 0 060 0 1 Part no MT65474 154 CORNER CONNECTOR EV 2 40 in clamped state 5 in clamped state CORNER CONNECTOR SPECIFICATIONS CORNER CONNECTOR EV 2 40 Resistance to misalignment N 1500 Fastening torque of screws Nm 6 Perpendicularity of clamping grooves mm
31. 0 55 Fa m 28 fas e pw s ERE EIN MONTRAC 47 ASSEMBLY EXAMPLE The support between the rails and the base frame is usually at the TracLink SLL DEK SLL DEK SLL SP 64 D SLL DEK SLL DEK more information about the components of the TracSet please refer to chapter TracSet starting on page 133 48 MONTRAC TRACSWITCH The TracSwitch is used to distribute Shuttles from one to two lanes or to collect Shuttles from two to one lane Thanks to the narrow radii bypasses and branches can be realized in a confined space The TracSwitch is operated electrically and is powered directly from the conductor rails Delivery options The TracSwitch can be ordered at montratec readily mounted and configured according to the desired switch type With the unconfigured TracSwitch the customer can assemble the conductor rails according to its application and can configure the TracSwitch himself The TracSwitch Configurator can be downloaded from the website www schmid group com TRACSWITCH SPECIFICATIONS Net weight kg 12 Material Aluminum nickel plated copper steel brass plastic Nominal voltage IV DC 24 min 228 max 20 9 Connections Lx R3232 3 x DIN per position used 1 x DIN 4 x DOT per position used 1 x DOT 1 x Error Rotation angle 3x 120 Rotation time 120 sec 1 2 Rotation time 240 sec 1 7 Torque of the rotary plate Nm 20 Curre
32. 0 x 400 mm single Platform 200 x 400 mm multiple Platform 300 x 400 mm multiple max 8 prisms Platform 200 x 550 mm single Platform 300 x 550 mm single Platform 200 x 550 mm multiple Platform 300 x 550 mm multiple max 12 prisms TRAC The monorail consists of a colorless anodized aluminium rod extruded profile The conductor rails can run along the left or right of the entire Trac thus allowing a flexible positioning of the control modules The Trac is compatible with the TracSet profile system TRAC SPECIFICATIONS Net weight Cross sectional area Section modulus Wx Section modulus Wy Moment of inertia Jx Moment of inertia Jy Length tolerance Torsion tolerance Straightness tolerance Material Nominal voltage Current carrying capacity Ambiance Temperature Rel air humidity Air purity level Minimum requirement compatibility kg m cm cm mm mm m mm m IV DC A PC MONTRAC 55 1957 2121 10 6 230 21 6 sro 1 1 Aluminum nickel plated copper plastic 24 64 10 to 40 5 96 85 96 without condensation normal workshop ambiance TracLink MT57949 DO 36 MONTRAC TRAC DIMENSIONS 1 2960 mm MT56926 2960 xxxx any length between 60 and 56926 2960 mm is available available P 115 55 e1 60 in mm steps e2 Guide profile conductor rail and cover profile are i
33. 000 EA 000000808 000 EA 000000840 000 EX 000001 101 000 16 012 0232 0000 98 MONTRAC TRACCONTROL 2 CONTROL COMPONENTS TRACCONTROL 2 IRM TC2 IRM The TracControl 2 IRM TC2 IRM is an opto electronic communication module for data exchange between the Shuttle and the controller allowing them to interact When the Shuttle is equipped with TracControl 2 it includes a 4096 byte FRAM which can be written with any data The TC2 IRM can function as a communication interface between the rail system and the TC2U or as an autonomously functioning control element such as a curve monitor The communication between TC2 IRM and the TC2U is performed using a CAN bus TracControl 2 components are not compatible with TracControl components as a different infrared transmission protocol is used for the TracControl 2 TRACCONTROL 2 IRM SPECIFICATIONS Net weight Power supply Current consumption at 24 V DC Max load current at 24 V DC Connections Dimensions L x W x H Ambiance Temperature Rel air humidity Air purity level g DC mA A mm PC 46 24 40 1 outputs shor circuit proof 2 identically configured 8 pin JST connectors 3 x DIN 22 DOT x 24 V 1 GND 1 8 pin JST connector 2 x CAN 2x 24V 2 x GND 102x36x11 10 to 40 5 85 without condensation normal workshop ambiance MONTRAC 99 TracControl 2 Part no MX TC2 IRM BASIC with cable detect start A und AB Cam
34. 300 mm and 300 mm x 550 mm Other sizes and the number and distribution of the positioning prisms are a customer specific choice Scope of delivery includes 4 center sleeves without processing of the prism specific processing of the platform for positioning of prisms or drill holes for superstructures can be done by the customer himself The production drawing for milling of platforms for positioning the prisms can be downloaded from the website at www montratec com under suppor forms If requested by the customer the prisms can also be placed by montratec AC PLATFORM SPECIFICATIONS Net weight 200 300 mm kg 29 200 400 mm kg 3 300 x 400 mm kg 5 0 200 550 4 6 300 550 kg On Ambience Temperature C 10 to 40 Rel air humidity 5 96 85 96 without condensation normal workshop Air purity level ambiance Minimum requirements compatibility Shuttle 3 and Shuttle MSH 4 34 MONTRAC PLATE DIMENSIONS Workpiece platforms platforms A x B max number without Prism prisms Part no 200 x 300 x 15 mm MT91677 200x400x15mm 8 MT56947 Travel direction 4 300 x 400 x 15 mm MT91683 20055505 15 MT56948 40 50 Tb mm MT56949 Special sizes on request min 55 min 40 MT46300 MT91811 Prism STANDARD DIMENSIONS Platform 200 x 300 mm single Platform 200 x 300 mm multiple max 5 prisms Platform 200 x 400 mm single Platform 30
35. 506157 Base frame type T MT56584 Single leg support MT56817 62 MONTRAC POSITIONS OF TRACCROSSING The TracCrossing has two possible positions Position Position 2 FREE SPACE FOR SHUTTLES WITH PLATFORM WIDTHS 200 MM 300 MM Depending on the load the free space will need to be increased upward eos 1 5 MONTRAC 63 CYCLE TIMES FOR TRACCROSSING Log off L The times mentioned below apply only to the configurations listed in the drawings and to the acceleration times listed below The dimensions shown in the drawings are minimum dimensions for which the manufacturer can guarantee trouble free operation CYCLE TIMES Twin Axle Shuttle Shuttle L2300 mm Shuttle L2400 mm Shuttle L2550 mm Shuttle L2550 mm LU 80 mm LU 2 180 mm L350 LU 2 350 mm Additional load Additional load Additional load Additional load without max without max without max without max Passage at 5 s s s s s s s v 30 m min 2 1 2 4 2 3 2 6 2 7 29 27 2 9 v 12 m min 4 3 4 5 4 8 om 9 7 9 0 228 9 9 The measurements for L assume a log off of the Shuttle at a falling signal at the log off sensor For a log off of the Shuttle at a rising signal of the log off sensor the value for L need to be increased by 70 mm each time 64 MONTRAC SUPOTRAC The serves as a product support at machining stations to prevent the Shuttle from being influenced by out
36. For firm base connections on floors or on table boards For the connection of two components arranged at right angles to each other and which can be individually adjusted BASE ANGLE AND ANGLE BRACKET SPECIFICATIONS 90 ANGLE BRACKET BASE ANGLE BW 40 KW 40 Weight kg 0 360 0 220 MT45715N MT45716N mo 158 MONTRAC ADJUSTING BRACKET EW 40 For the connection of two components arranged at right angles to each other and which can be individually fixed in two axis Adjusting bracket for angular joints ADJUSTING BRACKET SPECIFICATIONS ADJUSTING BRACKET ADJUSTING BRACKET EW 40 ROUND EWR 40 Weight kg 0 204 0 172 45851 45852 mo MONTRAC 159 ROTARY DISK 05 0 40 For attachment of two dovetails opposing each other which have to be arranged in any desired angle in twisted position to each other CROSS ELEMENT REINFORCED KEV 40 To connect two dovetails intersecting each other at right angles under high loads ROTARY DISK AND CROSS ELEMENT REINFORCED SPECIFICATIONS CROSS ELEMENT ROTARY DISK 05 0 40 REINEORCED KEV 40 Weight kg 0 024 0 077 Part no MT40857N MT46199N 160 MONTRAC SPACER ELEMENT LONG DEL 40 For connection of dovetail profiles under medium load SPACER ELEMENT SHORT DEK 40 For the connection of o
37. MT507529 TC T IRM configuration by montratec MT56944 TC1 IRM Configurator Unit MT58693 Box Single MT56984 Box Double MT56985 The TC1 IRM can be configured using the box and the PC interconnection cable MT57579 For current version of the software TC1 IRM ISM Configurator please refer to www schmid group com MONTRAC 87 ACCESSORIES FOR TRACCONTROL ELECTRICALLY SWITCHABLE CAM The electrically switchable cam is used in the following cases when a Shuttle is to be started backwards or if not every Shuttle is to stop at a defined position Electrically switchable cam power off for Shuttle visible 15 023 The electrically switchable cam is used the following cases when Shuttle is to be started backwards if not every Shuttle is to stop at a defined position Part no Electrically switchable cam on MT57024 power off for Shuttle invisible ELECTRICALLY SWITCHABLE CAMS SPECIFICATIONS Net weight kg 025 Connection voltage IV DC 24 Current consumption A OS Ambiance Temperature C 10 to 40 Rel air humidity 5 85 96 without condensation Air purity level normal workshop ambiance 88 MONTRAC FLAG A CAM FOR PU 4 CW MT57008 FLAG AB CAM MT58183 45 aod _ _ 23 To j 15 Th FLAG A CAM FOR PU 4 CCW MT57442 FLAG B CAM MT58184 107 _ _15_ 23 _ 5D 140 190 MONTRAC 89 ACCESSORIES FOR TRACCONTROL SHUTTLELOCK MT56925 DIM DRA
38. R THE CONFIGURATION SOFTWARE WITH UNLIMITED POSSIBILITIES The Montrac Configurator is a very easy to use and free software within which you can create individual transport system layouts with a few mouse clicks In the configurator all standard components of the Montrac system are stored in a product library These include for example Tracs Shuttles TracSwitches PositioningUnits base frames and much more With drag and drop the desired components are positioned in the configuration window The software detects the connection points by itself The operation is very simple and intuitive Should questions arise the integrated user manual provides detailed information on the layout design as well as the many other possibilities of this software These include for example creation of parts lists import of drawings and 3D export as well as various advices for an easier handling of the configurator SEQUENCE OF THE LAYOUT CREATION The configuration of a Montrac layout is very simple Whether based on known dimensions or on a hall drawing Tracs curves switches and other components can be placed at will The integrated design buttons at the end of a marked element allow the rapid continuation of the routing with single mouse clicks When Shuttles and TracControl components are placed a fully functional transport system is configured The configuration can be saved as a file and directly sent to the specialists for quotation management
39. RACSWITCH TRACSWITCH ARENA TRACCROSSING SUID OS ERGOTRAC POSITIONINGUNIT PU 4 TRACDOOR TRACCONTROL LIFT TRAC 1 ISOLATIONTRAC GROUNDING CONCEPT TRACSET BASE FRAMES SPECIAL COMPONENTS TRAC SEU Subject to modifications 24 28 2 So 216 4 48 54 60 64 67 2 81 84 100 109 23 8 MONTRAC MONTRAC THE SMART INTRALOGISTIC SYSTEM Montrac is an intelligent automation and transport system for interlinking industrial production and logistical processes and provides total flexibility reliability and efficiency when it comes to conveyor technology IN PLANT TRANSPORT INTRALOGISTICS Intralogistics and manufacturing processes are usually optimized up to the last second Our award winning Montrac system achieves a maximum material throughput with a minimum of cycle time and a very high system stability and guarantees a flexible expandability of the whole system ASSEMBLY AUTOMATION Montrac is compact fully modular and consists of system components In confined spaces or across several floors Montrac reliably and economically performs transport tasks in the assembly automation supports production tasks and processes from batch size one in any desired diversity of variants to high volume production PROCESS INTERLINKING Reliable and trouble free just in time operation of processing stations around the clock are tasks that are masterfully fulfilled by Montrac
40. U 4 deme SORA Increment b gt Twin Axle Shuttle with Shuffle NIS E Twin Axle Shuttle with with maximum load with maximum load 8 iud load is load S S 40 mm 0 82 0 82 0 66 0 66 50 mm 0 86 0 76 276 60 mm 0 90 0 94 0 85 0 85 80 mm 2 1 09 1 00 T00 100 mm 1 44 1 49 1235 150 mm 1 48 2 120 1 40 200 1 62 1 55 1 45 1 45 250 mm 1 79 722 1 60 1 60 300 mm 1 95 1 96 1 80 1 80 CYCLE TIME FOR INCREMENT d IN MULTIPLE POSITIONINGUNIT MPU 4 QIE Increment d gt Twin Axle Shuttle with Shuffle Twin Axle Shuttle with with maximum load with maximum load 8 load is load S S 250 mm 2 40 2 60 2 40 2 40 300 mm 222 2 80 2 60 2 60 350 mm 2 80 2 90 2 70 2 70 400 mm 200 3 10 2 80 2010 450 mm 3 10 3 20 2 90 2 90 Time measurement From the start command of the control element IRM in the PU to the presence signal of the control element IRM in the PU The rear Shuttle was positioned relative to the front Shuttle via the distance sensor distance 100 mm Following configuration of the cams was used Entrance speed 30 m min allowed only in protected area distance AB to A Cam 130 mm length A Cam 45 mm MONTRAC 79 MOUNTING SET FOR POSITIONINGUNIT PU 4 PLATFORM WIDTH 200 367 228 LN Mounting set for PU 4 platform width 200 mm MT65387 MOUNTING SET FOR POSITIONINGUNIT PU 4 PLATFORM WIDTH 300 MM
41. WING The ShuttleLock serves to localize a Shuttle at a hand work place or on the lift SHUTTLELOCK SPECIFICATIONS Net weight kg 0 560 Connection voltage IV DC 24 Current consumption A 05 Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance ACCESSORIES FOR SHUTTLELOCK Part no Proximity switch M4 PNP with cable and connector S8 for ShuttleLock MT520292 90 MONTRAC ACCESSORIES FOR TRACCONTROL 1 IRM BOX SINGLE DIMENSION DRAWING The Box single is used for wiring a Montrac system The Box Single is the interface between the and their peripherals or master control Since all the inputs and outputs of the can be picked up in the box it is universally usable TRACCONTROL 1 IRM ACCESSORIES SPECIFICATIONS BOX SINGLE MT56984 Net weight 9 160 Max cable cross section mm 0 5 Max cable diameter mm 5 Max voltage IV DC 24 Max current A 2 Ambiance Temperature C 10 to 40 Rel air humidity 5 85 96 without condensation Air purity level normal workshop ambiance ACCESSORIES FOR BOX SINGLE MT56984 Part no Cable for Box supply MT57184 PC connection cable MT57579 With the PC interconnection cable MT57579 and by means of a Shuttle the TC1 IRM can be configured using the box The latest version of the TC1 IRM ISM software
42. aded 30 m min with max add load Cycle time with max add load Sound pressure level Ambience Temperature Rel air humidity Air purity level Minimum requirements compatibility 1 Weight of Shuttle plate load capacity on page 31 mm kg kg mm m min m min m min V DC sec sec sec dBA PC Shuttle MSH 4 EE 343 5 20 19 0 2 1 2 8 Shuttle Shuttle MSH 4 MSH 4 400 mm L 550 mm 443 373 2 9 9 20 20 2017 30 12 55 24 30 0 1 0 1 22 0 7 1 1 2 1 2 025 99 3 0 2 2 203 10 to 40 MONTRAC 29 Twin Axle Shuttle MSH 4 273 8 8 38 0 15 1 6 1 8 Sl 2 2 5 96 85 96 without condensation normal workshop TracCurve starting from serial no 695586 XXX TracSwitch starting from serial no 722157 XXX ambiance TracSwitch Arena starting from serial no 691469 XXX Communication module OSMS3 TC1 IRM or TC2 IRM MONTRAC SHUTTLE MSH 4 DIMENSIONS 9 300 400 550 200 300 _ 170 270 1400 __ 65 _ 19 Other Shuttle lengths request TWIN AXLE SHUTTLE MSH 4 DIMENSIONS 200 1300 Twin Axle Shuttle MSH 4 Part no TC Part no TC2 M1 SH4 CW L550 2 2WD TC1 M1 SH4 CW L550 2 2WD TC2 MT61717 MT65287 MIsSHAsCCW L550 2 2WD IC M1 SH4 CCW 1L550 2 2WD 1C2 MT58783 MT65286 Other Shuttle lengths on request MONTRAC 31 SHUTTLE MSH 4 LOAD LIMITS The center of g
43. ail system communicating with the Shuttles material handling vehicles via infrared interface The control elements along the rail system can be controlled in a preconfigured setup autonomous operation by the TracControl 2 Unit or they can be controlled by customer specific systems semi autonomous operation Within a Montrac system autonomously and semi autonomously driven control elements can be mixed Simple Montrac system with TracControl 1 control OVERVIEW OF TRACCONTROL CONTROL VARIANTS Central Interfaces Variant Control elements philosophy control unit Hardware Protocol MDAC Montrac specific communication protocol based on UDP 20 MONTRAC TRACCONTROL 1 PositioningUnit TracSwitch ml ShuttleLock zE 2 D TC1 IRM Shuttle feb ene TC1 IRM E montra TC1 IRM TC T IRM Box Shuttle TC1 IRM HIGHER LEVEL 5 TracControl 1 is based on the so called Chaos Technology which makes possible to operate Montrac system independently autonomously of a higher level master control The Chaos Technology decouples the rail system from the process whereby the rail system establishes the logical connection between the process stations This means that the rail system is set up according to rules which support the process and provide optimum supply of goods to the stations So the Shuttle and the produ
44. al at the log off sensor For a log oft of the Shuttle at a rising signal of the log off sensor the value for L need to be increased by 70 mm each time CYCLE TIMES TRACSWITCH CURVE TracLink TracLink IRM A Cam MONTRAC 53 The times mentioned below apply only to the contigurations listed in the drawings and to the acceleration times listed below The dimensions shown in the drawings are minimum dimensions tor which the manufacturer can guarantee trouble tree operation CYCLE TIMES Shuttle L 300 mm Shuttle L 400 mm Shuttle L 550 mm 125 mm LU 2 225 mm LU 2 375 mm Additional load Additional load Additional load without max without max without max Passage at s s s s s s v 30 m min 20 22 2 2 2 4 2 9 2 8 v 12 m min 4 0 4 2 4 4 4 6 5 2 5 4 The measurements for L assume a of the Shuttle at a falling signal at the log off sensor Twin Axle Shuttle Shuttle L 550 mm LU 375 mm Additional load without max 5 5 2 6 21 5 4 9 9 For a log oft of the Shuttle at a rising signal of the log off sensor the value for L need to be increased by 70 mm each time 54 MONTRAC TRACSWITCH ARENA The TracSwitch Arena either diverts Shuttles into a bypass or allows them to continue on the main lane The TracSwitch Arena makes it possible to perform a complete bypass with a single component The TracSwitch Arena is operated electrically and is powered directly from the conductor rails
45. ccessory for TracCurve 45 R220 129 7 TracLink single leg support MT56817 MONTRAC 43 TRACCURVE 90 R520 DIMENSIONS TracCurve R520 90 R520 inside conductor rail MT58201 90 R520 outside conductor rail MT58207 Accessory for TracCurve 90 R520 Part no Base frame 90 MT58580 Base frame 180 MT58642 TRACCURVE 45 R520 DIMENSIONS TracCurve R520 45 R520 inside conductor rail MT58202 45 R520 outside conductor rail MT58208 Accessory for TracCurve 45 R520 44 MONTRAC FREE SPACE WITH PLATFORM DIMENSIONS 200 X 300 MM 300 X 400 MM WITH 90 TRACCURVE R220 Platform dimensions mm 200 x 300 R350 300 x 400 R400 RIO MONTRAC 45 FREE SPACE WITH PLATFORM DIMENSIONS 200 X 400 MM 200 X 550 MM 300 X 550 MM WITH 90 TRACCURVE R220 Platform dimensions mm Plattorm dimensions mm R380 R410 R800 R875 9 9 0 46 MONTRAC FREE SPACE WITH SHUTTLE TRACCURVE 90 R520 ps 170 e fe Platform dimensions 300 400 550 400 550 210 310 619 622 EN 7 woo 8 wm us Platform dimensions 300 400 550 400 55
46. ct controls the rail system selt reliantly The Chaos Technology is based on a defined address system In all decision points e g switches stations etc it is programmed into the TC1 IRMs The Shuttles have destination addresses that can be scanned at the decision points via the infrared interface and then pass on the Shuttle or the product accordingly MONTRAC 21 TRACCONTROL 2 TracSwitch WebGUI config status gt Compared to the TracControl 1 TracControl 2 interconnects the decision points modules along the rail system by means of a CAN bus and to manage the decision points via one or more central controls The configuration of 2 Unit TC2U The modules can be controlled in different modes Chaos Technology Control Technology or mixed operation The system status can be centrally recalled on the TC2U All log messages of the individual modules are transmitted via syslog Lift PositioningUnit Supolrac ShuttleLock E A Interface Ethernet Modbus TCP A n O s A bs i i T 2 ra TC2 IRM Shuttle TC2 IRM montra Shuttle TC2 IRM HICHER LEVEL CAN bus TC2 IRM Ethernet MDAC syslog NTP SSH the drive c
47. e electrically decoupled from one another by IsolationTracs Consequently in the event of short circuit on one of the sections only the maximum current of the power supply unit connected to this section can flow The IsolationTracs are supplied by means of DC DC converters ISOLATIONTRAC SPECIFICATIONS Nominal voltage Current carrying capacity Material Ambiance Temperature Rel air humidity Air purity level DC DC CONVERTER SPECIFICATIONS Input voltage Operating range Nominal input current Input power Output voltage Control accuracy of output voltage DC output current Output power Output voltage ripple Material Humidity class according to DIN 40040 Cooling Ambiance Temperature Rel air humidity Air purity level MONTRAC 111 These DC DC converters are IsolationTrac 660 mm is used in connected on the input side to the systems in which Shuttles are operated by two driven axles Iwin Axle Shuttle power rails of an installation section and on the output side to the IsolationTrac The DC DC converter limits the current on the IsolationTrac to max 4 2 A This current is sufficient for starting a Twin Axle Shuttle There are two lsolationTrac versions the IsolationTrac 300 mm and the IsolationTrac 660 mm IsolationTrac 300 mm is used in systems in which Shuttles are operated by a driven axle incl Shuttle with rear axle empty 24 40 Aluminum copper steel plastic
48. e material flow of a Montrac system in detail and to monitor the system status Communication with host systems and external components is additionally possible through standard interfaces The TC2 MFC guarantees intelligent monitoring and utilization of the Montrac system The positions of the shuttles and their destinations can be seen at any time by the material flow control In connection with the intelligent TracControl 2 controller all transport movements can be controlled and blockades and traffic jams avoided to achieve optimum utilization The user friendly MFC GUI graphical user interface can be displayed from any network PC with any standard browser Remote access facilities such as VPN are thus possible irrespective of your current location voa RB rene nid mj DE cen istae Fine Corb x E EL T Dass SEHMI a 1 bag i Fine Conor 11 5511 11411711 Ta Ti Sh PELE Pai x x 1 Wera Longi Thanks to integrated script processing the TC2 MFC can be efficiently adapted to the specifications of any project INTERFACES OF THE TC2 MFC TCP IP SECS GEM OPC MDAC Interface to the GUI of the TC2 MFC Interface for connection to the Host Manufacturing Execution System MES with the SECS GEM protocol Interface for communication with external control elements such as robots handling systems
49. e single multiple multiple multiple ACCESSORIES FOR POSITIONINGUNIT PU 4 Adjust gauge for width 200 mm Adjust gauge for width 300 mm Connection cable 5 m with straight socket on one side Connection cable 5 m with angled socket on one side Connection cable 10 m with straight socket on one side Connection cable 10 m with angled socket on one side Proximity switch 2 6 5 PNP with cable 2 m Platform top Description M1 PUA 5300 AI M1 PU4 S400M300 Al M1 PU4 S550M400 Al M1 PU4 S400M300 Al M1 PU4 S550M400 Al M1 PU4 M550 Al Part no MT65171 MT65173 MT504610 MT504929 MT507528 WilsO7 527 MT508842 Part no MT65092 MT65093 MT65094 MT65093 MT65094 MT65095 MONTRAC 75 PERMITTED FORCES AND TORQUES ON THE WORKPIECE CARRIER PLATFORM IN THE POSITIONINGUNIT Nominal pressure 5 bar Platform dimensions in mm aluminum platform locked in PU 4 200x300 200x400 300x400 200x550 300x550 MY perm Positioning single Nm MZperm Positioning multiple Nm Positioning single FXperm gene Positioning multiple Positioning single FY parr ge Positioning multiple Xmin 55 mm Ymin 25 mm The specified values cause the Shuttle platform to shift max 0 3 mm toward the force vector Note If several forces act simultaneously then the admissible forces for those special cases must be checked specifically 76 MONTRAC POSITIONINGUNIT MINIMUM TRAC LENGTH
50. e L2300 mm Shuttle L2400 mm Shuttle L 550 mm Twin Axle Shuttle Run in L min 95 mm 195 mm 345 mm 325 mm Move out L min 95 mm 195 mm 345 mm 345 mm MONTRAC 67 ERGOTRAC With the ErgoTrac a manual workstation can be set up more ergonomically The workpiece platform is tilted 25 towards the operator This makes the platform ergonomically more easily accessible and improves the visibility The ErgoTrac replaces a normal track piece at a length of 1160 m By means of the ShuttleLock the Shuttle is secured against movement while manual work is performed A simple support SupoTrac absorbs the forces that result from an operation taking place on the Shuttle The ErgoTrac can only be used for the Shuttle L2 300mm and L 400mm ERGOTRAC SPECIFICATIONS Net weight kg 12 Tilting time See table tilting times Tilt angle 23 Operating pressure bar 3 6 Nominal pressure bar 5 Air consumption at 5 bar cm cycle 144 6 Pneumatic connection Hose 2 4 6 2 7 4 Driving medium 5 filtered oiled or unoiled air End position monitoring Magnetically actuated cylinder switches Life time 107 switching operations Aluminum nickel plated copper plastic brass Material Steel bronze Nominal voltage DC 24 Current carrying capacity between the Trac connections A 40 on the movable Trac section A 23 Ambiance Temperature C 10 to 40 Rel air humidity 5 96 85 without condensation
51. e multiple single multiple multiple Net weight kg 8 2 9 11 11 14 Positioning accuracy horizontal x and y direction mm e C0 Se se OO e OHOTS vertical z direction mm 02 20 BENED O 022 2 Length mm 321 411 411 556 556 76 Operating pressure bar 3 6 Nominal pressure bar 9 Air consumption PU cm3 10 double stroke at 5 bar Pneumatic connection for hose with 4 mm Material aluminum steel bronze Driving medium 5 um filtered oiled or unoiled air Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance 72 MONTRAC POSITIONINGUNIT 1 4 5300 DIMENSIONS o Platform dimension 200 x 300 mm REEL LN M1 PU4 S300 Al MT65092 POSITIONINGUNIT M1 PU4 S400M300 Al DIMENSIONS jb SPU 4 SPU 4 MPU 4 mm 200x400 300x400 200x300 1 4 5400 300 165093 MONTRAC 73 POSITIONINGUNIT M1 PU4 S550M400 Al DIMENSIONS Plattorm SPU 4 5 1 4 MPU 4 MPU 4 dimensions 200 x 300x 200 300 550 400 400 E DETERE 3e se M1 PU4 S550M400 Al 65094 POSITIONINGUNIT M1 PU4 M550 Al DIMENSIONS Platform dimensions MPU 4 MPU 4 200 x 550 300 x 550 1 4 550 165095 74 MONTRAC WORKING HEIGHT POSITIONINGUNIT Platform length mm 300 400 550 300 400 550 Positioning single singl
52. ed position Full Open by 1 revolution Exon incl ned 16 Empty 1 1 Open by 1 revolution horizontal position Full 1 1 Open by 1 revolution 70 MONTRAC SUPPORT ON A TRACSET PROFILE BASE FRAME Support by means of single leg supports part no MT5681 7 and support for ErgoTrac MT58594 MEHR pm F E 4334 mE zem mT mimus ode Single leg support i Support for ErgoTrac ingle leg support part MT5681 7 part no MT58594 part MT5681 7 i B 1200 SUPPORT ON A TABLETOP USING TRACSET Support on tabletop by means of a TracSet frame base for Trac tabletop part no MT54819 and TracSet base frame for TracLink tabletop part no MT57431 TracSet base frame for TracSet base frame TracSet base frame for TracLink tabletop part for Trac tabletop TracLink tabletop part no MI57431 part no MT54819 no MT57431 MONTRAC 71 POSITIONINGUNIT PU 4 The PositioningUnit PU 4 is used when a Shuttle is to be precisely positioned and or when the platform must be additionally supported during the machining operation There are versions for single and multiple positioning SPU 4 and MPU 4 Both versions are available in various sizes corresponding to the standard platform dimensions POSITIONINGUNIT PU 4 SPECIFICATIONS pneumatic PositioningUnit for platform length 300mm 300mm 400mm 400mm 550mm 550mm singl
53. ed to a minimum a flexible extension is possible at any time As an option communication is possible with external control elements e g PLC or RS232 interfaces TRACCONTROL 2 TracControl 2 allows different operating modes such as Chaos Technology Control Technology or a mixed operation Modules consisting of standardized Montrac components are controlled by the central control unit TracControl 2 Unit TC2U Configuration and control of the modules can be performed centrally by the TC2U The TC2U provides for instance an Ethernet hardware interface to communicate with other controls or host computers For this purpose the UDP based MDAC protocol Montrac specific protocol is used MDAC allows a guide system to control and monitor the Montrac system As with TracControl 1 communication with external control units can be performed via 1 signals TRACCONTROL 2 In addition to the scope of TracControl 2 the material flow can be controlled and visualized and the process data can be recorded by means of a Material Flow Controller MFC The MFC provides interfaces which use the SECS GEM protocol the MDAC protocol and OPC protocol This allows to communicate with Host Manufacturing Execution Systems MES or third party devices such as robots MONTRAC 19 CONTROL VARIANTS OF THE MONTRAC SYSTEM BASIC PRINCIPLE OF COMMUNICATION Programmable control elements TC2 IRM are arranged along the Montrac monor
54. h Montrac we were able to realize several objectives at one time we saved time optimized control of production processes and efficiency of labor and improved our space utilization Maurizio Romagnoli owner of Tech Pol s r l Based on a positive result gained in a previous project we know we can find a suitable solution to satisfy the requirements in terms of compact dimensions small footprint compatibility with aseptic environments reliability and high availability Thomas Otto CEO of Vetter Pharma Fertigung GmbH amp Co KG We are very satisfied with the result and service of montratec We are currently planning the implementation of two more Montrac lines Ulrich Wilke Production Manager of SEIKO Optical Europe Laboratory MONTRAC 5 6 MONTRAC montratec AG The montratec AG with its place of business in Gerlafingen Switzerland is a company within the SCHMID Group and is specialized in the development manufacturing and the marketing of the automated transport system Montrac Montratec s service includes the consulting and engineering of customized projects ranging from single components of the catalog to complete turnkey system solutions including flexible control concepts Montrac is the most flexible economic and reliable automation system for transport tasks within a company intralogistics efficient assembly automation solutions and systematic process interlinking of industrial production and logistic
55. htnesstolerance Straightness tolerance Weight Part no for length 2000 mm mm cm cm mm m mm m kg m ADAPTER PROFILE AP 40 40 271 022 axe 0 14 272 according to DIN 7168 medium 1 D MT41258N2000 Precision aluminum rod extruded profile acc to DIN 17615 hardened warm anodized natural end face cut nearly burr free Designed for the production of adapters Precision aluminum rod extruded profile acc to DIN 17615 hardened warm anodized natural end face cut nearly burr free Designed for the production of adapters ADAPTER PROFILE AP 56 40 600 1 04 4 83 0 67 13 59 according to DIN 7168 medium 1 0 7 1 620 46253 2000 MONTRAC 147 MULTIPLE CABLE DUCT 40 Precision aluminum rod extruded profile acc to DIN 17615 hardened warm anodized natural end face cut nearly burr free Snapable profile for the laying of pneumatic hoses and electric cables MULTIPLE CABLE DUCT KFM 40 SPECIFICATIONS Length tolerance according to DIN 7168 medium Weight kg m 0 549 Part no for length 2000 mm MT45229N2000 148 MONTRAC FIXED SCREEN PROFILE FFP 40 Precision aluminum rod extruded profile acc to DIN 17615 anodized natural end face cut nearly burr free FIXED SCREEN SPECIFICATIONS Length Tolerance according to DIN 7168 medium Weight kg m 0 570 Part no for length 2000 mm MT45159N2000 COVER 16 40 AK 66 40
56. huttles are the intelligent material handling vehicles and the centerpiece of every Montrac system Owing to their special shape they ride self centered on the monorail They are powered by a maintenance free low voltage motor which is located in the Shuttle axle A Shuttle is available with one or two drive axles The speed and the stop position of the Shuttle can be determined by means of cams which are screwed to the T grooves of the Trac Using pre configuration of the speed parameters individual customer needs can be addressed best The maximum running speed of Shuttle MSH 4 amounts to 55 m min Additional loads up to 30 kg are possible Each Shuttle has a sensor system by means of which it detects other Shuttles and obstacles on the rail system Shuttle MSH 4 can be controlled with TracControl 1 and 2 When TracControl 2 is used for control Shuttle MSH 4 includes a 4096 byte FRAM on which any data can be written Advantages of Shuttle MSH 4 Preconfigurable speed Max speed 55 m min a Robust mechanics Additional loads up to 30 kg are possible Additional interface SHUTTLE MSH 4 SPECIFICATIONS Shuttle Length Weight Max total weight Stopping accuracy over n Shuttles Running speed Reduced running speed vas Increased max speed for defined sections Supply voltage during standstill at vs 30 m min at vs 55 m min when accelerating Power consumption Acceleration time unlo
57. igh precision scales from Eilersen and a base frame which is independent of the Trac The workpiece platforms are lifted and can be weighed exactly down to 1 gram vibration free depending on the required weight range The scales features a RS 486 or a Profibus interface This module is especially used in the intralogistics and also for assembly processes as check weigher MONTRAC 133 TRACSET TracSet is a patented assembling system with cross product compatibility and flexibility Its proven dovetail mounting system permits quick and easy assembly of all montrac components TracSet a technology with countless possibilities Advantages of TracSet Precise heavy duty vibration proof connection Suitable for static and dynamic application With the screws tightened to 6 Nm torque the resistance to displacement for the two interconnected protiles is 3000 N An Allen key is sufficient for assembly ROBUST AND FLEXIBLE Precise heavy duty vibration proof connections between two elements with dovetail geometry by means of clamping elements For static as well as dynamic use With the screws tightened to 6 Nm torque the resistance to displacement for the two interconnected profiles is 3000 N 227 134 MONTRAC TracSet is a universal modular system for structural framing The system allows quick assembly without mechanical processing of the profile ends With a minimum of
58. individual elements 10 basic components a great variety of assembling possibilities is possible TracSet can be adjusted easily quickly and flexibly No drilling and no pinning are necessary TracSet is suitable for precise and dimensionally stable connections Its dovetail connections can be subjected to larger loads than the T slot connections With the screws tightened to the correct torque the resistance to displacement for two interconnected profiles is 3000 N A Easy fast and flexible Variety Precise and dimensionally stable MONTRAC 135 TracSet connections are vibration proof and therefore highly suitable for demanding applications The connections are precise regardless of the profile end processing TracSet allows to set up linear connections as well as connections with adjustable angles Its high flexibility permits the structural frames to be subsequently reinforced vertical supports horizontal bars diagonal struts All the clamping screws in the structural framing are always accessible The base frames are easy to disassemble at a later time for reuse thanks to the clamping connections no drill holes are necessary Accessible Vertical Diagonal Can be subjected to high loads Reusable 136 MONTRAC TRACSET COMPONENTS OVERVIEW Figure Description Support profile 2 Light profile Support profile Support profile Adapter profile gt Adapter profile
59. ions of bypasses are stored in the integrated library These frequently used assemblies can be easily positioned in the layout by means of drag amp drop There is also the possibility to store specially created assemblies in a personal library Thus the creation of the next Montrac layout will be even more simple The Montrac Configurator can be downloaded free from the website www schmid group com 18 MONTRAC TRACCONTROL THE VERSATILE MONTRAC CONTROL For controlling the Montrac system TracControl components are used which are also of modular design and which can be dimensioned depending on the requirement profile Customer requirements Complexity of the application field intralogistics assembly automation process interlinking Required interfaces to customer supplied systems Flexibility and extensibility Material flow control and material management Data logging From a simple fully autonomous transport track to complex networked transport and manvfacturing systems for automated manufacturing the TracControl of Montrac offers the tailor made and flexible control solution TRACCONTROL CONTROL SYSTEM TracControl 2 TracControl 2 TracControl 1 Interfaces protocols Performance TRACCONTROL 1 TracControl 1 is a drive control based on Chaos Technology where the rail system is decoupled from the process and no higher level control is needed Costs and complexity are reduc
60. ly unlimited possibilities combined with user friendly simplicity of the entire system For more than fifteen years Montrac has optimized global production and intralogistics processes of innovators More and more there is a requirement to choose the most efficient way If productivity is to be increased the first thought is to increase the number of machines But this is not always necessary The more cost effective and faster way to increase the productivity is to automate and or optimize the material flow This is hardly practicable with classical conveyor systems Montrac can quickly easily flexibly and conveniently help with this project MONTRAC 1 11 OVERVIEW OF THE MONTRAC COMPONENTS SHUTTLE The Shuttles are the intelligent material handling vehicles and the centerpiece of every Montrac system A Shuttle is available with one drive axis or as a Twin Axle Shuttle Each Shuttle has a sensor which prevents potential collisions with obstacles or other Shuttles TRAC The monorail consists a colorless anodized aluminium rod extruded profile The conductor rails can run along the left or right of the entire Trac thus allowing a flexible positioning of the control modules The Trac is compatible with the TracSet profile system TRACLINK The TracLink is the connecting element between two Trac sections connects the conductor rails and serves as feeding point as well as support point
61. m LU 2 330 mm Additional load Additional load Additional load Additional load without max without max without max without max Passage at 5 5 5 5 5 5 5 5 30 m min 1 8 2 0 2 0 2 9 22 2 2 4 2 7 v 12 m min 37 4 1 4 3 4 8 5 0 9 6 9 9 50 The measurements for L assume a log off of the Shuttle at a falling signal at the log off sensor For a log off of the Shuttle at a rising signal of the log off sensor the value for L need to be increased by 70 mm each time MONTRAC 59 CYCLE TIMES FOR TRACSWITCH ARENA CURVE TracLink 80 OT AB Cam A Cam IRM A Cam AB Cam The times mentioned below apply only to the contigurations listed in the drawings and to the acceleration times listed below The dimensions shown in the drawings are minimum dimensions for which the manufacturer can guarantee trouble tree operation CYCLE TIMES Twin Axle Shuttle Shuttle L 300 mm Shuttle L 400 mm Shuttle L 550 mm Shuttle L 550 mm L 125 mm 225 mm LU 375 mm LU 375 mm Additional load Additional load Additional load Additional load without max without max without max without max Passage at 5 s s s s s s s v 30 m min 1 7 1 9 2 0 22 2 9 2 6 2 4 2 4 12 m min 9 6 4 0 4 4 4 4 8 2 5 0 5 4 The measurements for L assume a log off of the Shuttle at a falling signal at the log off sensor For a log of of the Shuttle at a rising signal of the log off sensor the value for L need to be increased by
62. m and the master control or as a control element operating autonomously The communication between the master control and the IRM takes place at predefined connector pins or via the serial interface on the TC1 IRM TracControl 1 components are not compatible with TracControl 2 components as a different transmission protocol is used for the TracControl 2 TRACCONTROL 1 IRM SPECIFICATIONS Power supply IV DC 24 Power consumption mA 25 with 24 V DC Max load current A 1 with 24 V DC outputs short circuit proof Connections 2 identically configured 10 pin JST connectors 165232 3 DIN 3 X DOT Dimensions mm 102 x 36 11 length x width x height Net weight 9 39 Ambiance Temperature ke Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility Shuttle 3 Shuttle MSH 4 MONTRAC 85 INTERFACES The electric plug connections on the TC1 IRM are divided into three sections Power supply 24 V DC Digital inputs outputs which can be allocated to a specific function via a configuration e g Shuttle Start Shuttle Detect Shuttle Lock log off etc for conventional operation with external control and or for TC1 IRM logic function incl chaos technology Serial interface RS232 communication interface for reading and writing the Shuttle identification number group or ID for Shuttle control in networked systems stat
63. meters 10 meters 15 meters 20 meters 10 meters 15 meters 20 meters 10 meters 15 meters 20 meters Part no 57463 57457 MT59422 MT57644 MT57629 MT57958 MT56936 MT90759 MT520319 MT520320 141520321 1520322 1520323 1520324 57470 MT57614 MT57615 MT520360 10000 MT520360 15000 MT520360 25000 MT520361 10000 MT520361 15000 MT520361 25000 MT58562 MT58558 MT58560 MT520325 MT520326 MT520445 MT520393 MT57910 5 7911 5 7912 MONTRAC 109 TRACSUPPLY The TracSupply is used for supplying the power rails of the Montrac transport system with 24 VDC Via these power rails the Shuttles are supplied with their energy during the ride The output voltage is 24 V DC short circuit proof and open circuit proof The TracSupply consists essentially of a power supply timed on the primary side contactors and fuse elements For operating it is equipped with a main switch an illuminated button for switching on the supply and a button for switching off the supply The TracSupply can also be switched on and off via PLC The TracSupply available in two capacities one with 40 ampere and one with 2x 40 ampere output current In order to guarantee that never more than the allowed 40 ampere are connected to the rail system the plant must imperatively be divided into sections by using IsolationTracs when having the stronger system version The number of Shuttle axles used decides o
64. n the Montrac transport system changes of Trac direction by 90 or 45 are realized by processed Tracs There are no shocks acting on the Shuttles when traveling through a TracCurve The cross section of TracCurve is identical to the Trac Using two 90 TracCurves a 180 curve can be constructed The TracCurve R520 is used under certain special conditions e g heavy product weight and extremely high sensitivity to vibrations The connection radius of 220 mm 520 mm gives Montrac unparalleled flexibility 2 x TracCurve 90 2 x TracCurve 90 R520 TRACCURVE SPECIFICATIONS 20122 457 R220 JORI ZO 45 R520 Net weight kg 2 0 1 4 5 0 2 8 Material Aluminum nickel plated copper plastic Nominal voltage IV DC 24 Current carrying capacity A 64 Length tolerance mm 0 0 Ambiance Temperature e Ore Ae Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility TracLink MT57949 42 MONTRAC TRACCURVE 90 R220 DIMENSIONS 0 20 0 5 TracCurve R220 90 R220 inside conductor rail MT56095 90 R220 outside conductor rail MT56096 260 Accessory for TracCurve 90 R220 Part no 1 TRACCURVE 45 220 DIMENSIONS 115 TracCurve R220 45 R220 inside conductor rail MT56097 45 R220 outside conductor rail MT56098 A
65. n the power of the TracSupply required for a plant TRACSUPPLY SPECIFICATIONS 40 power supply 2 x 40 A power supply 24 axles 48 axles Input voltage 3 x 400 Mains frequency Hz 50 60 Input voltage range IV AC 380 500 Frequency range Hz 47 63 Switch on current A 25 2325 Input power at nominal load kW 25 20 Harmonic filtering Integrated passive filter according to EN EC 61000 3 2 DC at output IV DC 24 28 8 adjustable Control accuracy of output voltage 1 3 96 from set value DC at output max A 40 2 x 40 Output voltage ripple mV 200 Current limitation adjustable 10 11096 A Max 44 max 2 x 44 Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Cooling Natural air cooling 110 MONTRAC TRACSUPPLY DIMENSIONS Luminous Push button flat red pushbutton Circuit breaker Hat green Emergency Stop TracSupply 40 A MT60506 TracSupply 2 x 40 A MT60508 Use always in connection with IsolationsTrac FASTENING SET FOR POWER SUPPLY DP 40 L 500 Square sliding block 6 460 ISOLATIONTRAC It the power requirement for a larger plant with many Shuttles is bigger than 40 A the plant supply must be divided up into appropriate sections These are supplied by a separate supply unit each These sections ar
66. ncluded in the scope of delivery View A View B ACCESSORIES FOR TRAC Part no Guidance profile 9041 6 Conductor rails 508346 Cover profile MT91257 hoox T slot cover L2 3000 mm Duos Base frame for Trac MT54819 Single leg support MT91565 for Trac Trac double leg support MT91569 for TracLink Trac 3 leg support MT57948 4 leg support MT58301 MONTRAC 37 MECHANICAL LOAD CAPACITY During installation the potential number of fully loaded Shuttles on a Number of fully loaded Shuttles track section needs to be considered permissible length of a track section supported at both ends Depending on this number the without with reinforce monorail must be supported over N TP 66 certain track sections ee The permissible length of a track section supported at both ends Lperm depending on the number of Shuttles T must comply with the following table LM The Trac 1 can also be equipped Fm with a reinforcement 2 TP 66 In E this case the permissible length of a supported track section may be e 46 21 larger see table below c a bun 2 m 4 3 E Shuttle LTrac 1 2 4m 3 2 m ASSEMBLY EXAMPLE The support between the rails and the base frame is usually at the TracLink SLL SLL DEK DEK SLL SLL DEK DEK SLL SLL SP 64 D For more information about the components
67. ned by means of cams which are screwed to the T grooves of the Trac The maximum running speed of Shuttle 3 amounts to 30 m min Additional loads up to 25 kg are possible Each Shuttle has a sensor system by means of which it detects other Shuttles and obstacles on the rail system Shuttle 3 can be controlled with TracControl 1 and 2 When TracControl 2 is used for control Shuttle 3 includes a 4096 byte FRAM on which any data can be written SHUTTLE 3 SPECIFICATIONS Shuttle Length Stopping accuracy Max running speed Vmax Reduced running speed vreg Max weight Shuttle weight without platform Static moment around the longitudinal axis Supply voltage Power consumption during standstill GEV aay when accelerating Accelerating time unloaded with max add load Sound pressure level Ambiance Temperature Rel air humidity Air purity level 1 Weight of Shuttle plate load capacity on page 26 2 Until 0 95 x Vmax is reached mm mm m min m min kg kg Nm V DC sec sec dBA PC Shuttle 3 300 400 550 30 12 17 3 8 4 1 4 6 287 24 0 08 0 80 2 24 0 85 1 40 Twin Axle Shuttle 3 rear axle empty 550 221110 30 12 17 5 2 lt 4 24 0 08 0 80 2 24 0 85 1 40 lt 59 1910 20 Twin Axle Shuttle 3 550 30 12 34 70 lt 4 24 0 16 1 20 4 48 0 80 1 10 5 96 85 96 without condensati
68. ng bracket Adjusting bracket round Rotary disk Abbreviation EV 3 40 pack of 4 EV 4 40 pack of 4 EVD 4 40 SP 64D 40 STA 40 BW 40 KW 40 EW 40 EWR 40 05 0 40 Part no 165469 165471 165472 MT41133N MT57637 MT45715N MT45716N MT45851N MT45852N MT40857N Page 154 155 1955 156 156 157 157 158 158 159 MONTRAC 139 TRACSET COMPONENTS OVERVIEW Figure Description Abbreviation Part no Page Cross element reinforced KEV 40 MT46199N 159 Spacer element long DEL 40 MT57446 160 Spacer element short DEK 40 MT57447 160 Bracket for protective screen 55 40 48310 161 Hinge 5 40 MT45160N 161 Articulated foot for support profile GF 96 40 MT44019 162 Articulated foot for support profile GFTP 66 40 MT54295 162 Articulated foot for light profile GFLP 66 40 MT49397 162 Swivel caster for support profile LRTP 75 40 MT54267 163 Swivel caster for light profile LRLP 75 40 MT54269 163 140 MONTRAC TRACSET COMPONENTS OVERVIEW Figure Description Fixed caster for support profile Fixed caster for light profile Foundation anchor bracket Abbreviation 75 40 75 40 FW 40 Part no MT54268 MT54270 MT46201N Page 164 164 169 SUPPORT PROFILE 16 40 MONTRAC 141 Precision aluminum rod extruded profile acc to DIN 17615 hardened warm anodized natural end face cut
69. nsport of the Shuttles This compact and space saving litt is easy to operate and has been especially designed for small height differences The lift is especially low maintenance as well as durable thus very cost efficient Protection of employees in the lift area is imperative SHUTTLE WITH ADDITIONAL POWER SUPPLY 24V 3 A can be supplied on the Shuttle The Twin Axle Shuttle with empty back axle serves as the basis The power supplied for an additional component located on the Shuttle can be collected via an additional current collector built in in the back axle The Shuttle with power supply is used in different industrial sectors e g for autonomous loading or unloading of a Shuttle with transport belt MONTRAC 129 130 MONTRAC SHUTTLE WITH TRANSPORT BELT Transport belts adapted to special requirements are firmly attached to the Shuttle Thus every Shuttle carries along the loading and unloading unit whereby partially complex handling stations become unnecessary The power for the transport belt is directly supplied via the Shuttles 24 V 3 A FLEXTRAC Montrac manages to overcome certain height differences with the FlexTrac e g between machines and processing stations without using a lift Depending on the application different ascent angles are possible MONTRAC 151 132 SCALES MODULE The scales module consists of a Supolrac with integrated h
70. nt carrying capacity between the Trac connections A 40 on the movable Trac section A 2 5 Mechanical load capacity N 340 Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility TracLink MT57949 corresponds to the weight of a fully loaded Twin Axle Shuttle TRACSWITCH DIMENSIONS 172 Free space 2 150mm 167 ACCESSORIES FOR TRACSWITCH Configuration by montratec PC connection cable Flag for TracSwitch Base frame type T Base frame for double TracSwitch Base frame type H 252 Free space 150 Part no MT56935 MT506157 MT57456 MT56584 MT56826 MT58230 MONTRAC 49 Part no MT58734 20 MONTRAC OVERVIEW OF TRACSWITCH TYPES The TracSwitch has three possible positions Based on these possibilities the TracSwitch can be used as a TracSwitch Divide distributor switch or as a TracSwitch Collect merge switch TRACSWITCH DIVIDE TYPES TracSwitch Divide L TracSwitch Divide T TracSwitch Divide R Pos IRM IRM 1 4 Pos 4 is equal to Pos 1 turned by 360 Depending on the application different TracSwitch positions are necessary TRACSWITCH COLLECT TYPES TracSwitch Collect L TracSwitch Collect T TracSwitch Collect R Pos Pos 4 is equal to Pos turned by 360 Depending on the application different TracSwitch p
71. nts using 1 signals in the same way as the TracControl 1 CONFIGURATION TC2U The WebGUI available on the TC2U with which all modules and the TC2U are configured can be easily called up using any web browser Secure Shell Connection SSH is available to access the TC2U in order to undertake customer specific settings read out log files or carry out a software update As the TC2U can be integrated in a network remote maintenance is easily realized DATA LOGGING The embedded Linux operating system on the TC2U contains BusyBox and thus syslog With this log messages from all modules and the TC2U are transferred through the Ethernet interface and can be collected by a syslog server The TracControl 2 is very easy and fast to wire thanks to plug in connections 94 MONTRAC TRACCONTROL 2 UNIT TC2U SPECIFICATIONS Number of connection slots 2 4 6 8 10 Net weight without plug in boards kg 0 7 0 9 1 1 1 3 1 2 Length mm 25 205 285 BOS 445 Input voltage IV DC 24 Current consumption at 24 V DC mA 200 without plug in boards Min input voltage inputs IV DC 22 4 Max input voltage inputs IV DC 22 Current consumption per input mA 3 Output voltage outputs IV DC Input voltage Max output current per digital output mA 500 Max output current per 1 board mA 3500 Max output current per TC2U mA 6000 Material Aluminum copper steel brass plastic lype of protection IP 20 Ambiance Temperature 10 to 40 Rel ai
72. o 40 Humidity class F without condensation with relative moisture 85 96 normal workshop ambiance LIFT CHAOS TECHNOLOGY LCT SWITCHING CABINET SPECIFICATIONS Nominal voltage Nominal power Type of protection Installation type Weight Dimensions L x W x V AC IW kg mm 3 x 400 480 V 50 Hz 60 Hz 800 12221 vertical 92 600 x 380 x 350 104 MONTRAC SWITCHING CABINET LCT DIMENSIONS 600 400 397 Switching cabinet LCT Part no Variant 1 2 3 Level MT58558 Variant 2 4 7 Level MT58560 MOUNTING SET FOR SWITCHING CABINET LCT SLL 55 40 SP 64D 40 DEK 40 EE DP 40 1 600 545 397 Square sliding block M8 for LCT switching cabinet MT59620 MONTRAC 105 L CONNECTION TRAC DIMENSIONS R Connection Trac dimensional drawing mirror inverted 121 Connection Trac complete 57463 Connection Trac complete 57457 BASE FRAMEWORK FOR LIFT without safety screens 955 Sample Dimensions for Lift Upper edge of Shuttle platform 900 mm stroke 1000 mm 106 MONTRAC LIFT FIXTURE ON A TRACSET STRUCTURAL FRAMINC max 500 min 230 io l
73. ocal control modules communicate with the Shuttles and control the line autonomously 200 000 150 000 100 000 1 50000 o Project planning Cabling Valves Assembly Software Pallet Nr Line cost Maintenance 6 y Energy 6 y Compressed air 6 y The following cost comparison resulted from a customers analysis A conveyor belt system with 34 motors 11 stations and 48 pallets was compared to a Montrac system for the same application 24 Shuttles also with 11 stations The initial price of the Montrac system is slightly higher than the price of the conveyor belt system But already with the project planning wiring mounting and control Montrac is far below the price of the competitors The cost comparison over 6 years results in a cost advantage of 46 96 for the Montrac system MONTRAC 15 CHAOS TECHNOLOGY Chaos Technology is a method of allowing the Shuttles to operate the rail system of a Montrac transport system independently of a master control The Chaos Technology originated from the possibility to link identity characteristics with control commands to allow track components to operate autonomously The master control is relieved from the duties related to the temporally and functionally correct activation of rail system control elements Thus on master control level more attention can be given to the machining processes in the processing stations CHAOS TECHNOLOGY WITH TRACCONTROL TracC
74. ol system which receives its commands from the control cams on the Trac Possible collisions with other Shuttles or obstacles are detected by an integrated sensor and prevented by appropriate control commands The Shuttles are characterized by their smooth running and minimum energy consumption The platforms on which the workpieces are accommodated can be lifted off the Shuttles The Shuttle MSHI 4 Inductive is mainly used in the cleanroom for manufacturing sensitive products such as hard disks wafers or medical products 126 MONTRAC RFID SHUTTLE With the RFID Shuttle the transported product not the Shuttle as before determines the route through the transport system Attached to the product on the Shuttle there is a tag or transponder containing a code with the route through the Montrac system The RFID Shuttle provides added automation streamlining of the material flow BELT LIFT The belt lift has been optimized for cleanroom applications and allows the vertical transport of Shuttles This special lift is reliable as well as maintenance free and extremely dynamic and precise Thus the following jobs can be managed Connecting two or more systems of different work heights Taking Shuttles from a station to a ceiling system or vice versa Protection of employees in the lift area is imperative MONTRAC 27 128 MONTRAC PNEUMATIC LIFT The pneumatic lift allows the vertical tra
75. on normal workshop ambiance MONTRAC 25 SHUTTLE 3 DIMENSIONS 200 300 9 300 400 550 20 165 Other Shuttle lengths on request TWIN AXLE SHUTTLE 3 DIMENSIONS 200 300 9 550 20 165 CCW rear axle empty Other Shuttle lengths on request 26 MONTRAC SHUTTLE 3 LOAD LIMITS The center of gravity of the load should be centered and not higher than 130 mm above the Shuttle For more information see operating manual of Shuttle 3 11211111 TWIN AXLE SHUTTLE 3 LOAD LIMITS AXLE EMPTY mn load capacity 17 kg ms mp transported parts including their mounting on the platform mp platform weight see table on page 33 ms Shuttle weight see table on page 24 The center of gravity of the load should be centered and not higher than 130 mm above the Shuttle For more information see operating manual of Shuttle 3 L4 LJ E LJ LL LJ mn load capacity 17 kg ms mp mp platform weight see table on page 33 ms 6 2 kg MONTRAC 27 TWIN AXLE SHUTTLE 3 LOAD LIMITS The center of gravity of the load should be centered and not higher than 130 mm above the Shuttle For more information see operating manual of Shuttle 3 mn load capacity 34 kg ms mp mp platform weight see table on page 33 ms 9 kg 28 MONTRAC SHUTTLE MSH 4 The S
76. ontrol 1 IRMs TC1 IRM are used to control the track and the Shuttles by means of Chaos Technology The Shuttles can receive and permanently save identification numbers group and ID They can also receive start commands When the Shuttle is being positioned it emits an InPos signal via infrared signal along with the stored identification numbers The can receive InPos signals and identification numbers from the Shuttle and directly pass them on to an interface Due to their configuration the TC1 IRM can emit status signals and control signals to the interface and react logically when configured appropriately CHAOS TECHNOLOGY WITH TRACCONTROL 2 The modules connected to the central control unit TracControl 2 Unit TC2U can be operated by means of Chaos Technology Control Technology or a mixed operation In doing so the operating mode may be defined for each module In contrast to TracControl 1 a Shuttle ID 4 bytes and a destination address 4 bytes is stored in the Shuttle when using the TracControl 2 Since a modern infrared transmission protocol is used in the TracControl 2 control elements these are not compatible with the TracControl 1 control elements The TC2 IRM reports the Shuttle ID and the Shuttle destination address to the TC2U via the CAN bus This reacts according to its configuration ADDRESSING THE COMPONENTS All processing stations and components of the Montrac rail system that are connected to a logistics sys
77. ontrol is performed centrally on the TracControl MDAC Montrac specitic communication protocol based on UDP 22 MONTRAC TRACCONTROL 2 TracSwitch PositioningUnit WebGUI contig status E A Intertace Ethernet Modbus TCP I O interface TC2 IRM Shuttle TC2 IRM montra Shuttle TC2 IRM CAN bus TC2 IRM HICHER LEVEL CONTROL SYSTEM Ethernet MDAC HTTP syslog NTP SSH SECS GEM OPC Building on TracControl 2 a Material Flow Controller MFC is further integrated in the TracControl Advanced allowing for material flow indication material flow control and data logging All relevant data such as position status destinations etc as well as system warnings are clearly displayed MEC SECS GEM The MFC has various connection options to control systems for example via SECS GEM protocol as well as to third party components with OPC interfaces or comparable systems MDAC Montrac specitic communication protocol based UDP MONTRAC 23 APPLICATION EXAMPLE FOR A MONTRAC SYSTEM MECHANICAL LAYOUT IN 3D VIEW CREATED WITH CONFIGURATOR SOFTWARE SCHEMATIC REPRESENTATION WITH SENSORS CONTROL ELEMENTS AND WIRING TRACCONTROL 1 In case of TracControl 1 the IRMs are wired on terminal strips in the Box Single and B
78. ositions are necessary 1 TracSwitch Collect T An additional flag part no MT57456 must be mounted on the TracSwitch Collect T since the Shuttles move toward each other and may blind each other with the distance sensor this could lead to faults Line of sight Distance sensor MONTRAC 51 FREE SPACE FOR SHUTTLES WITH PLATFORM DIMENSIONS 200 X 300 MM 200 X 400 MM 200 X 550 MM Depending on the load the free space will need to be increased upward Platform dimensions Depending on the load the free space will need to be increased upward RIO R300 200 300 x 400 300 x 550 225 229 480 22 MONTRAC CYCLE TIMES TRACSWITCH STRAIGHT ON Log off TracLink TracLink IRM A Cam The times mentioned below apply only to the contigurations listed in the drawings and to the acceleration times listed below The dimensions shown in the drawings are minimum dimensions tor which the manufacturer can guarantee trouble tree operation CYCLE TIMES Twin Axle Shuttle Shuttle L 300 mm Shuttle L 400 mm Shuttle L 550 mm Shuttle L 550 mm L 40 mm LU 160 mm L 330 mm L 330 mm Additional load Additional load Additional load Additional load without max without max without max without max Passage at 5 5 5 5 5 5 5 5 30 m min 2 2 9 23 2 6 2 6 2 2 7 2 9 v 12 m min 4 2 4 5 4 8 Sel 9 7 9 0 9 7 59 The measurements for L assume a log off of the Shuttle at a falling sign
79. ox Double According to the function the required sensors and actuators are connected to these In addition the interfaces digital inputs outputs and RS232 are available on the terminal blocks TRACCONTROL 2 With TracControl 2 all cables can be easily and quickly connected to the respective components via plug in connections Autonomous components are not connected to the system All components belonging to modules are connected to a TC2U either directly by means of sensor cable actuator cable or via the CAN bus The TC2U can be linked to a customer supplied system via Ethernet The digital interface of the TC2 IRM can be directly picked up on these or on the TC2U CAN cable Double Box Single Log out sensor 0 Track switch cable Sensor cable Ih Log out sensor TC2 IRM CURVE ae i 2 F rack switch Sensor cable cable 24 MONTRAC SHUTTLE 3 The Shuttles are the intelligent material handling vehicles and the centerpiece of every Montrac system Owing to their special shape they ride self centered on the monorail They are powered by a maintenance free low voltage motor which is located in the Shuttle axle A Shuttle is available with one or two drive axles The speed and the stop position of the Shuttle can be determi
80. r humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance TRACCONTROL 2 UNIT DIMENSIONS 511 55 40 TC2U Length L mm MXTC2U 2SLOT MT60533 MXITC2U 4SLOT 21877 21 651 MT61694 MXTC2U 8SLOT MT61695 MXTC2U 10SLOT MT61992 MONTRAC 95 TRACCONTROL 2 ACCESSORIES PLUG IN BOARDS FOR TRACCONTROL 2 UNIT TC2U MX TC2U TS Card Plug in board for TC2U MX TC2U TS Card Part no MT61574 Net weight 9 69 1 x M12 for TracSwitch 2 x M8 for log off sensor Connections TC2U ACCESSORIES Power supply cable M8 4 pin 2 m Blank cover TC2U net weight 40 g Cover for socket connector 3 5 mm Socket connector 3 5 mm 30 p PUSHIN PNP LED Socket connector 3 5 mm 10 p PUSHIN PNP LED Socket connector 3 5 mm 30 p screw in Code element for socket connector Connection resistor CAN SMD fuse 2 A SMD fuse 4 A SMD fuse 6 3 A MX TC2U IO Card 4 7 e MX TC2U IOO Card i galvanically isolated 1 MX TC2U IO Card MX TC2U MT61575 MT61576 46 27 8 DIN 8 x DIN galvanically isolated 8 x DOUT 8 x DOUT galvanically solated Part no MT521155 MT61578 MT521149 EX 000003065 000 EX 000003066 000 EX 000003068 000 000003067 000 1521129 000000 83 000 000000 82 000 EF 00000044 7 000 96 MONTRAC TRACCONTROL 2 MFC The TracControl 2 Material Flow Controller TC2 MFC is used to visualize control and record th
81. ravity of the load should be centered and not higher than 130 mm above the Shuttle For more information see operating manual of Shuttle MSH 4 amp mn load capacity 20 kg ms transported parts including their mounting on the platform digni see table on page 33 ms Shuttle weight see table on page 28 TWIN AXLE SHUTTLE MSH 4 LOAD LIMITS The center of gravity of the load should be centered and not higher than 130 mm above the Shuttle For more information see operating manual of Shuttle MSH 4 4 4 platform weight see table on page 33 4 ms Shuttle weight see table on page 28 32 MONTRAC FREE SPACE FOR SHUTTLE 3 AND SHUTTLE MSH 4 WITH WORKPIECE PLATFORM 200 X 300 MM 200 X 400 MM 200 X 550 MM 210 170 L1 L Trac length Boundary line the area within this boundary line must remain free Depending on the load the free space will need to be increased upward FREE SPACE FOR SHUTTLE 3 AND SHUTTLE MSH 4 WITH WORKPIECE PLATFORM 300 X 400 MM 300 X 550 MM 310 1705 105 S L1 L Trac length Boundary line the area within this boundary line must remain free Depending on the load the free space will need to be increased upward MONTRAC 33 WORKPIECE PLATFORM The workpiece platforms are the link between the products and the Shuttle The platforms are available in various sizes between 200 mm x
82. ree for material storage or for further processing steps With the Montrac system material handling vehicles with different transport tasks and pallet sizes can be used on the same rail system CLEAN ROOM Thanks to its shape and the use of purely electrically driven components Montrac is designed as standard for the clean room Thanks to an improved development certain components have now been certified by the Fraunhofer Institute for Production Technology in clean room class 4 The use of Montrac in clean room ranges from the production of sensitive products such as hard disks and wafers up to the transport of medicine and plastic containers for medical applications MONTRAC 7 10 MONTRAC MONTRAC THE MODULAR AUTOMATION AND TRANSPORT SYSTEM Montrac is completely modular can be freely and flexibly configured and thus can be easily extended at any time Montrac consists of three main categories in which the intelligent Shuttles material handling vehicles are the heart of every Montrac system In addition a configurator software is available Montrac components TracSet profile system TracControl control elements a Software Montrac configurator The monorail track system is defined with a selection of system components For a flexible routing features such as curves switches and lifts are available Montrac offers corresponding components for specific process or processing
83. s processes for automated manufacturing Innovative customers from different industrial sectors automotive photovoltaics plastics medical optics batteries semiconductor technology food etc have benefited from the unique advantages for more than 15 years and use the Montrac system successfully around the world GOOD DESIGN product design award 2013 m Montrac award winning monorail transport system SCHMID Group SCHMID has been inventing solutions for dynamic industrial sectors for 150 years achieving impressive growth by successfully entering into new business fields and international markets The SCHMID Group covers a wide range of key technology competencies in wet processes thermal and vacuum processes printing metalization vision and inspection laser technology as well as automation and intralogistics Out of this wide ranged technology portfolio SCHMID develops innovative solutions in its technology centers and turns those into tailor made process technology for existing and new application fields The SCHMID Group manufactures worldwide with more than 2 000 employees in Germany Switzerland Taiwan Japan China and the USA and has numerous sales and service branch offices around the world www schmid group com INDEX OF CONTENTS MONTRAC 7 ABOUT MONTRAC CHAO MONTRAC CONFIGURATOR TRACCONTROL S SHUTTLE MSH 4 WORKPIECE PLATFORM TRAC TRACLINK TRACCURVE T
84. sary parameters can be configured Further the TC1 ISM Intelligent Shuttle Module in the Shuttle can be assigned a new Shuttle number 67 5 TRACCONTROL 1 IRM ACCESSORIES SPECIFICATIONS CONFIGURATOR UNIT Net weight kg Material Aluminum copper steel plastic Connection voltage IV AC 90 284 Frequency Hz 47 63 Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance MONTRAC 93 TRACCONTROL 2 COMPONENTS TracControl 2 offers many ways of controlling a Montrac system Here modules comprising individual standardized Montrac components are controlled by a Montrac TracControl 2 Unit TC2U TRACCONTROL 2 UNIT TC2U The TC2U is the central control unit of the Montrac system when this is controlled by TracControl 2 Standardized modules consisting of individual Montrac components such as TracSwitch TC2 IRM CAN and sensors are connected to it with the CAN bus or digital inputs outputs The TC2U is available with a varying number of board slots in order to insert switch boards digital boards The TC2U provides for instance an Ethernet hardware interface to communicate with other controls or host computers For this purpose the UDP based MDAC protocol Montrac specific protocol is used The interface allows a guide system to control and monitor the Montrac system The TCU can communicate with external control eleme
85. side forces The ShuttleLock included in the scope of delivery prevents the Shuttle from being moved manually out of the IRMs operating area during processing The SupoTrac is not suitable for stations with press operations The Supofrac further makes claims concerning ergonomics or safety regulations for manual workstations SUPOTRAC SPECIFICATIONS Net weight kg 4 2 Connection voltage ShuttleLock IV DC 24 Current consumption ShuttleLock A 05 Material aluminum copper plastic brass steel rubber Ambiance Temperature 10 to 40 Rel air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance SUPOTRAC DIMENSIONS MONTRAC 65 300 400 550 62 _ 314 14141564 424 1524 674 SupoTrac with ShuttleLock _ 7 297 7 250 6 for platform widths 200 and 300 MT56933 ACCESSORIES FOR SUPOTRAC Single leg support TracLink plate base frame Connection cable 5 m with straight socket on one side Connection cable 5 m with angled socket on one side Connection cable 10 m with straight socket on one side Connection cable 10 m with angled socket on one side Proximity switch M4 with cable and connector 58 for ShuttleLock Part no MT56817 5 7431 MT504610 MT504929 507528 MT507529 MT520292 66 MONTRAC MINIMUM DISTANCE UNTIL CHANGE OF DIRECTION 400 k 1 m I L min d L min Run in Move out GAPS Shuttle Shuttl
86. t for TracLink TracLink MT58298 119 DOUBLE LEG SUPPORT FOR TRACLINK TRAC 900 mm to top edge of Shuttle platform Double leg support for TracLink Trac MT58299 900 mm to top edge of Shuttle platform 3 leg support for TracLink MT57948 120 MONTRAC 4 LEG SUPPORT E N 652 346 560 900 mm to top edge of Shuttle platform Part no 158301 4 leg support 900 mm to top edge of Shuttle platform TS base frame type L Part no MT56818 MONTRAC 121 TS BASE FRAME TYPE T e g for 2 x TracCurve 90 TracSwitch TracCrossing 2 5 504 727 900 mm to top edge of Shuttle platform E TS base frame type T MT56584 5 BASE FRAME TYPE 900 mm to top edge of Shuttle platform o TS base frame type H MT58230 122 MONTRAC 5 BASE FRAME FOR DOUBLE TRACSWITCH 2 5 504 900 mm to top edge of Shuttle platform TS base frame for double TracSwitch MT56826 700 568 900 mm to top edge of Shuttle platform F 9 TS base frame for TracSwitch Arena 57671 225 6 MONTRAC 123
87. tem are for example numbered consecutively These numbers correspond to the addresses according to which the Shuttles orientate themselves in the system The principle of the Chaos Technology is that upon completion of a working process in a processing station the Shuttle is given the next destination address All control elements which are configured for Chaos Technology autonomously respond to the destination address causing the Shuttle to independently reach the next station The code is simply the identification number group and ID in case of TracControl 1 and or the Shuttle ID and destination address in case of TracControl 2 These are stored in the Shuttle and can be changed if necessary THE PRODUCT CONTROLS THE RAIL SYSTEM A Shuttle announces its presence by sending a specific message Among other things this message includes the identification numbers or the Shuttle ID and destination address The TC1 IRM and or TC2 IRM receives the message and passes it on By sending the starting signal together with the code from the TC1 IRM and or TC2 IRM the Shuttle is started Based on this systematics the code of a Shuttle is communicated at each stop position and can be linked to a decision This link ensures that the Shuttle transporting a specific product and having certain identification numbers and or Shuttle ID and destination address branches off at a junction and any otherwise addressed Shuttle does not 16 MONTRAC MONTRAC CONFIGURATO
88. tion cable 502127 Base frame MT57671 56 MONTRAC OVERVIEW OF TRACSWITCH ARENA POSITIONS AND TYPES Pos Pos 2 Pos 3 1 4 1 4 The desired TracSwitch Arena type can be configured with the Motor Configurator software The latest version can be downloaded from the website www schmid group com Pos 4 is equal to Pos 1 turned by 360 MONTRAC 57 210 FREE SPACE FOR SHUTTLES WITH PLATFORM DIMENSIONS 200 X 300 200 X 400 200 X 550 Platform dimensions Depending on the load the free space will need to be increased upward TE ES co pn mn Lr ELE 280 310 Depending on the load the free space will need to be increased upward 300 x 400 R400 300 x 550 R410 R440 R875 335 475 590 58 MONTRAC CYCLE TIMES FOR TRACSWITCH ARENA STRAIGHT ON 7 80 x Qi LLLA e jy A The times mentioned below apply only to the configurations listed in the drawings and to the acceleration times listed below The dimensions shown in the drawings are minimum dimensions for which the manufacturer can guarantee trouble free operation CYCLE TIMES Twin Axle Shuttle Shuttle L2300 mm Shuttle L2400 mm Shuttle L2550 mm Shuttle L2550 mm LU 40 mm LU 2 160 mm LU 2 330 m
89. us indication visualization etc MONTRAC TCT IRM CONFIGURATION The Montrac ISM configurator configures the desired TC1 IRM type and the corresponding parameters There are 14 module types available from a drop down menu as a standard version The range of functions includes everything from curve monitoring to autonomous actuation of TracSwitches The locking of the Shuttle e g at a manual working station can be controlled via the as well This software can also be used to read and re write Shuttle identification numbers The latest version is available under www montratec com ACCESSORIES CONNECTION BOXES AND CABLES An TC T IRM is needed at each stopping point in the system to detect a present Shuttle and to start the Shuttles The Basic assembly serves this purpose It consists of a a connection cable AB cam speed reduction and an A cam stop Various connection kits are available for specific uses connection box terminal box for a single TC1 IRM with or with out proximity switch holder connection box for two TC1 IRMs with one proximity switch holder and connection box for one TC1 IRM with two proximity switch holders When using the Montrac Configurator the TC1 IRMs and the respective kits can be assigned automatically Thus at the push of a button a correct material list can be generated TRACCONTROL 1 IRM DIMENSIONS TC1 IRM Intelligent Routing Module
90. uter dovetails under medium load SPACER ELEMENT SPECIFICATIONS SPACER ELEMENT SPACER ELEMENT LONG DEL 40 SHORT DEK 40 Weight kg 0 110 0 080 Pan no MT57446 AIEO MONTRAC 161 BRACKET FOR PROTECTIVE SCREEN 55 40 M5 Hole diameter 8 mm protective screen in clamped state HINGE 5 40 Hinge of aluminum anodized natural for swing doors SPECIFICATIONS BRACKET FOR PROTECTIVE SCREEN AND HINGE BRACKET FOR PROTECTIVE SCREEN H55 40 0 034 0 300 MT48310N MT45160N HINGE S 40 162 MONTRAC ARTICULATED FOOT GF 96 40 FOR SUPPORT PROFILE TP 96 40 Foot made of black plastic with vibration absorber spindle of steel galvanized with corresponding adapter for profile TP 96 40 Foot made of black plastic with vibration absorber spindle of steel galvanized with corresponding adapter for profile TP 66 40 Foot made of black plastic with vibration absorber spindle of steel galvanized with corresponding adapter for profile LP 66 40 ARTICULATED FOOT SPECIFICATIONS COE TED FOO 2 120 ED NICU TED GF 96 40 FOR GFTP 66 40 FOR GFLP 66 40 FOR SUPPORT PROFILE SUPPORT PROFILE LIGHT PROFILE TP 96 40 TP 66 40 LP 66 40 Max load in axial direction kN 12 5 5 Weight ka 0 865 0959 0 400 Part no 44019 MT54295 MT49397 MONTRAC 163 SWIVEL CASTER LRTP 75 40 LRLP 75 40 MAUN 122 142 122
91. with 34 kg load m s 235 Max positions Gear motor Nom motor capacity W 550 Type of protection IP 54 Encoder system Resolver Feedback system External measuring system Reference point initiator External inductive proximity switch PNP Sound pressure level dBA 66 Operating temperature of motor 65 CYCLE TIMES OF SHUTTLE IN LIFT Cycle times s Shuttle Shuttle Shuttle Twin Axle Shuttle rear axle empty Twin Axle Shuttle Travel time of lift with up to17 kg load Travel time of lift with up to17 kg load Travel time of lift with up to 34 kg load Travel time of lift with up to 34 kg load Travel time for cycle platform length 300 mm 400 mm 550 mm 550 mm 550 mm stroke lt 0 45 m stroke gt 0 45 m stroke lt 0 9 m stroke gt 0 9 m Forwards in forwards out s 4 5 4 8 5 0 5 0 5 9 2 mc 2 travel time s Stroke in m 0 45 1 9 Stroke in M 9 travel time s 245 Stroke in m 0 9 1 5 MONTRAC 101 Forwards in backwards out s 6 3 6 3 6 3 ors 6 5 0 6 travel time s 1 2 travel time s cycle time of Shuttle 2 x travel time of lift total cycle time Shuttle moves in lift travels shuttle moves out and lift travels back 102 MONTRAC LIFT DIMENSIONS 613 5 0006 4 1 4661 095 X ANH 1 uon2es 9981 08 1 9644 sze

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