Montrac - Montratec
Contents
1. EPV 200x300 of shuttle pallet QS Framework for TracCurve 45 R500 mit FW 900 mm to top edge 58589 Pallet size 200 56846 EPV 300x400 EPV 300x550 MPV 300x400 MPV 300x550 Pallet size 300 56847 80 MONTRAC QS FRAMEWORK FOR PV 2 3 PALLET WIDTH 200 MM 2 5 504 80 5 460 QS FRAMEWORK FOR 2 3 PALLET WIDTH 300 MM 560 727 EPV single posi tioning MPV multiple positioning 900 mm to top edge of shuttle pallet Re No Pallet width 200 mm with FW 91586 727 EPV single posi tioning MPV multiple positioning 900 mm to top edge of shuttle pallet RefNo Pallet width 300 mm with FW 91588 136 150 260 5 245 5 185 5 X Y EPV 300x400 260 5 EPV 300x550 245 5 MPV 300x400 245 5 MPV 300x550 185 5 QS FRAMEWORK 1 FOR TRACDOOR 504 80 5 767 MONTRAC 81 900 mm to top edge of shuttle pallet po QS Framework 1 for TracDoor 2000 3000 with FW 92064 900 mm to top edge of shuttle pallet Re No QS Framework 2 for TracDoor 2000 with FW 92066 82 MONTRAC MONTRAC 83 INTELLIGENT ROUTING MODULE IRM INTELLIGENT SHUTTLE MODULE ISM INTELLIGENT ROUTING2. Increasing productivity thanks to flexible and intelligent intralogistics 10 2011 English edition MONTRATEC REFERENCES mi SA Autoliv PRETTL FARRAR ABR dutem ESCHENBACH Boehringer Ingelheim Km HELLA ideen fiir das Auto der Zukunft REEMTSMA gt MAGNA T VIMAR RADINE Energia positiva THE QUALITY CONNECTION 4 ENG LEONI C20 C HK automation a a FE Sala oUrgess 3Saehringer Ingelheim CHIRON VACCINE Pharmaton bhcinoe 34 551 4 MONTRAC MONTRAC IN USE BY Antistatic and low power consumption Efficient and fully automated intralo gistics Flexibility for the future Wilh 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 With Montrac we have saved time optimized production processes and the efficiency of labor and freed up space Maurizio Romagnoli owner of Tech Pol s r l Based on a positive result gained in a project we know we can find a suitable solution to satisty 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
3. oO C0 ELN OG O N m Q o e o 9 0 D LO o OS os LO 0 JC E c LO O o e 11 O i LL L L Stroke in the example dimensional drawing 1000 mm To top edge of shuttle pallet 900 mm When ordering specity bottom position and maximum stroke Magnetic tape 10 120 850 min 595 MONTRAC 4 2000 L 80 1855 stroke X 560 1680 L F 96 Trac section L 185 300 330 390 2 570 700 42 MONTRAC CONTROL SET FOR LIFT 58562 TECHNICAL DATA SERVO POSITIONING CONTROLLER 9300 type EVS9322 EP Rated current Rated current with mains filter Auxiliary voltage supply Protective class Installation type Weight BRAKE UNIT 9350 type EMB9352 E Supply voltage Peak current for 60s Max continuous current Protective class Installation type Weight MAINS FILTER type EZN3A1500H003 Rated voltage Peak current for 60s Max continuous current Protective class Installation type Weight Ambient conditions temperature rel humidity air purity ADC ADC kg ADC ADC kg Re 3 x 380 480V 50 Hz 60 Hz 2 5 24VDC 0 15 5A IP 20 vertical switch cabinet 3 9 270 775 42 25 2
4. Standard Shuttle 300x400 plattorm alu LU 225 mm payload without 5 MONTRAC 31 1 The measurements for L assume a sign off of the shuttle for a falling signal from the sign off sensor For a sign off of the shuttle for a rising signal from the sign off sensor the values for L will need to be increased by 70 mm in each case Standard and 2 axle 2 axle Shuttle Shuttle rear axle 300x550 platform empty 300 x 550 alu platform alu LU 330 mm 1 330 mm payload payload without without 5 s 1 The measurements for L assume a sign off of the shuttle for a falling signal from the sign off sensor For a sign off of the shuttle for a rising signal from the sign off sensor the values for L will need to be increased by 70 mm in each case Standard and 2 axle 2 axle Shuttle Shuttle rear axle 300x550 platform empty 300 x 550 alu platform alu 375 mm L 375 mm payload payload without without 5 s 32 MONTRAC TRACSWITCH ARENA The TracSwitch Arena either diverts Shuttles into a bypass or allows them to continue on the main Trac The TracSwitch Arena makes it possible to perform a complete bypass with a single component The TracSwitch Arena is electrically operated and is powered directly from the conductor rails Delivery options You can order the TracSwitch pre contigured for a specific task You can mount the conductor rails and configure the contro
5. 255 210 90 R500 outside conductor rail 58207 TRACCURVE 45 R500 DIMENSIONAL DRAWING Pallet oy um 200x400 200x550 300x400 300x550 B 8650 8650 8770 R600 8850 C o s s o C 62 o ws 25 ars 25 225 _ p ome 233 233 134 8202 45 R500 outside conductor rail 58208 28 MONTRAC MONTRAC 29 TRACSWITCH TRACSWITCH DIMENSIONAL DRAWING The TracSwitch diverts Shuttles from one Trac to two or merges two Tracs Thanks to the small radius bypasses and branches can be implemented in small spaces The TracSwitch oper 252 ates electrically and is powered directly from the conductor rails Free space Free space Delivery options 150 150 mm mm You can order the TracSwitch pre contigured for a specific task You can mount the conductor rails and configure the controller as required for your application The montratec Motor Configu rator software is available at www montratec com Re No 58734 Flag for TracSwitch optional 57456 OVERVIEW OF TRACSWITCH TYPES TracSwitch divide L TracSwitch divide T TracSwitch divide R TRACSWITCH TECHNICAL DATA TracSwitch weight kg 12 Material aluminium nickel plated copper steel brass plastic Rated voltage VDC 24 min 22 8
6. LP 66 40 AK 66 40 SLL 55 40 KW 40 SLL 55 40 Re No Mounting bracket for wall 57910 955 Example dimensional drawing for a lift to top edge of shuttle pallet 900 mm stroke 1000 mm 700 260 180 260 50 MONTRAC MOUNTING OPTIONS FOR FALL GUARD AND STOP Lift X Lift T x T Foll guord 59422 Box for fall guard 57644 57629 57958 SHUTTLE Shuttles are intelligent transport vehicles They are available with a single axle drive or two axle drive Shuttles are propelled by a 24 volt brushless DC motor Maximum speed is 30 m min Maximum permissible load is 25 kg Each Shuttle is equipped with a sensor that prevents collisions with obstacles or other Shuttles SHUTTLE TECHNICAL DATA Shuttle Length Stop precision Maximum running speed Vmax Reduced running speed Vmin Total weight Shuttle weight without pallet Longitudinal axis static moment Supply voltage Current consumption when at standstill at Vmax when accelerating without load with max load Acceleration time Noise pressure level Ambient conditions temperature rel humidity air purity mm mm m min m min kg kg Nm VDC A A A sec sec dBA PC 1 Weight of Shuttle pallet payload see load limits on page 53 2 Until 0 95 x Vmax is reac
7. Nd INTR 900 mm to top edge of shuttle pallet 3 foot support with FW for TracLink 5 948 Support for ErgoTrac 58594 76 MONTRAC MONTRAC 77 QS FRAMEWORK TYPE L e g support for a TracCurve 90 QS FRAMEWORK FOR DOUBLE TRACSWITCH 280 504 80 5 900 mm to top edge 900 mm to top edge of shuttle pallet of shuttle pallet 346 Reh No QS Framework type L with FW 56818 700 x N 504 727 727 L N 154 6 900 mm to top edge of shuttle pallet 900 mm to top edge of shuttle pallet x Re No QS Framework type T with FW 56584 QS Framework for TracSwitch Arena with FW 57671 78 MONTRAC MONTRAC 79 QS FRAMEWORK FOR TRACCURVE 90 R500 QS FRAMEWORK FOR TRACCURVE 180 R500 926 7 1221 885 D 1 E 727 735 2496 _ 525 900 mm to top edge of shuttle pallet 900 mm to top edge of shuttle pallet QS for TracCurve 180 R500 with FW 58642 1340 QS Framework for TracCurve 90 R500 mit FW 58580 SET TO FASTEN FOR PV 2 3 SP 64D 40 330 430
8. We are very satisfied with the result and service of montratec Currently we are planning the implementation of two more Montrac lines Ulrich Wilke Production Manager of SEIKO Optical Europe Laboratory Montratec manufactures modular components used to automate demanding production and logistic processes In addition to conventional belt conveyors automation components and the Quick Set profile system our range of products features the Montrac transport system Montrac is an intelligent transport system for networking industrial production and logistic processes Montratec headquartered in Switzerland has been pioneering advances in indus trial automation since 1963 Montrac is an intelligent conveyor system for industrial production and logistical processes Montrac exemplifies total flexibility when it comes to conveyor technology provid ing virtually limitless possibilities combined with user friendly simplicity throughout the entire system Montrac has been optimizing production processes and intralo gistics in innovative companies worldwide for over a decade The Montrac intra logistic solution guarantees that products are arriving at the proper destination at the right time More importantly it takes the most efficient path When one wants to increase productivity the first thought is often to increase machinery However this is not always necessary The quickest and most cost effective way to increase your pro
9. mox 28 8 Connections R5232 3 DIN per used positions 1 x DIN 4 DOT per used positions 1 x DOT 1 x Error Rotation angle 3 x 120 Rotation time 120 sec 1 2 Rotation time 240 sec 1 7 Current carrying capacity between the Trac connections A 64 on the moveable Trac section A 215 Mechanical load capacity N 340 Ambient conditions temperature FC 10 to 40 rel humidity 5 85 without condensation air purity normal workshop atmosphere corresponds to the weight of a fully laden 2 axel shuttle The desired TracSwitch type can be configured with the montratec Motor Configurator software The latest version is available at www montratec com 30 MONTRAC FREE SPACE FOR SHUTTLES WITH PALLET SIZE OF 200x300 200x400 200x550 The clearance will need to be increased upward depending on the load 200x300 200x400 200x550 A o RO R30 The clearance will need to be increased upward depending on the load RUN TIMES TRACSWITCH STRAIGHT ON Sign off TracLink Standard Shuttle 200x300 plattorm alu LU 40 mm payload without Passage at s TracLink TracLink IRM A Cam Standard Shuttle 300x400 plattorm alu 1 160 mm payload without 5 Sign oft Standard Shuttle 200x300 plattorm alu LU 125 mm payload without Passage at s TracLink IRM A Cam
10. 200x550 oo e M Ee O T 3 210 The clearance will need to be increased upward depending on the load 1 200x300 200x400 200x550 105 220 280 R350 R350 R380 E 210 310 155 424 The clearance will need to be increased upward depending on the load RUN TIMES TRACSWITCH ARENA STRAIGHT ON 80 MONTRAC 35 AB Cam Sign oft Standard Shuttle Standard Shuttle 200x300 plattorm 300x400 plattorm alu alu LU 40 mm 1 160 mm payload payload without without Passage at s s RUN TIMES TRACSWITCH ARENA STRAIGHT ON TracLink 80 ET un 1 The measurements for L assume a sign off of the shuttle for a falling signal from the sign off sensor For a sign off of the shuttle for a rising signal from the sign off sensor the values for L will need to be increased by 70 mm in each case Standard and 2 axle 2 axle Shuttle Shuttle rear axle 300x550 platform empty 300 x 550 alu platform alu LU 330 mm 1 330 mm payload payload without without s s AB Cam Sign off SF Standard Shuttle Standard Shuttle 200x300 plattorm 300x400 plattorm alu alu LU 125 mm LU 225 mm payload payload without without Passage at s s 1 The measurements for L assum
11. c 180 mm adhered by Stop Start Device s Pallets 300 x 400 mm c adhered by distance sensor c 180 mm adhered by Stop Start Device Pallets 200 x 550 mm c adhered by distance sensor c 180 mm adhered by Stop Start Device Pallets 200 x 550 mm Two Axle Shuttle 3 rear axle empty c adhered by distance sensor c 180 mm adhered by Stop Start Device Pallets 200 x 550 mm Two Axle Shuttle 3 c adhered by distance sensor c 180 mm adhered by Stop Start Device s s s s s s s s cycle time with pallet aluminium unloaded 285 2 88 3 07 3 09 7 350 2 3 36 3 49 3 44 with max load 201 272 3 34 SZ 3 44 3 40 339 Time measurement From the start command of the control device up to the presence signal of the control device in the positioning unit without locking time and unlocking time CYCLE TIME OF THE SHUTTLE IN THE POSITIONING UNIT MULTIPLE MPV b Travel direction CYCLE TIME b IN THE POSITIONING UNIT MULTIPLE MPV step size b mm 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 23 Shuttle 3 cycle time with pallet alum payload without s max s 0 80 0 82 0 81 0 83 0 82 0 85 0 84 0 8 0 85 0 88 0 8 0 89 0 88 0 90 0 89 0 92 0 90 QS 0 92 0 95 5 0 9 0 94 0 98 0 96 0 99 0 97 1 00 0 98 1 02 1 00 1 03 1 01 0 s 1 02 1 06 107 1 05 1 09 1 06 1510 1 07 1 12 1 0
12. mm 5330 Max permitted load kg 34 Max speed m s 1 5 Max acceleration with 17 kg load m s2 5 Max acceleration with 34 kg load m s 25 Max positions 7 Drive drive motor Motor rated power W 550 Protective class IP 54 Encoder system resolver Return system external measurement system Reference point initiator external inductive proximity switch PNP Noise pressure level dBA lt 66 Motor operating temperature 65 40 MONTRAC CYCLE TIME OF THE SHUTTLE IN THE LIFT Forwards into lift forwards out Cycle time s pallet length 5 Shuttle 300 mm 4 5 Shuttle 400 mm 4 8 Shuttle 550 mm 5 0 Two Axle Shuttle rear axle empty 550 mm 5x10 Two Axle Shuttle 550 mm 5 3 Travel time litt up to 17 kg capacity E Travel time lift up to 17 kg capacity 1 5 Travel time litt up to 34 kg capacity stroke lt 0 9 m 2 3 Travel time litt up to 34 kg capacity stroke gt 0 9 m Travel time for cycle Shuttle pull into the lift the lift moves shuttle drives out and the litt proceeds back stroke lt 0 45m stroke in m 2 travel time s stroke gt 0 45m stroke in m 0 45 0 6 travel time s V stroke in m 9 travel time s stroke in m 0 9 02 L 1 2 travel time s Cycle time of the shuttle 2 x travel time Lift total cycle time LIFT DIMENSIONAL DRAWING Forwards into lift backwards out or vice verse s 6 3 Onc 6 3 6 3 6 5 CN ll OX e
13. 57579 PC connection cable via the box The latest IRM ISM Configurator software version is available at www montratec com SHUTTLELOCK Ref No ShuttleLock 56925 Proximity switch M4 PNP with cable and plug 58 520292 PROXIMITY SWITCH COMPATIBILITY CONNECTION CABLE CYLINDER SWITCH Components proximity switch connecting cable cylinder switch Ref No Ref No Ref No Ref No Segment anchor M 12x80 5 507557 508842 508845 520292 504610 504929 506879 506885 Cable guide KFM 40 L 2000 mm 45229N2000 Holder for signal transmitter x 1 Cable guide KFM 40 L 0025 mm 45229N0025 PV 2 3 1 2 Supolrac E 1x E 2 2 1 2x 2 TracDoor 1 1 ShuttleLock 1 _ _ FLEXIBILITY FOR INNOVATORS ONLY montratec montratec AG Zielmattenring 6 CH 4563 Gerlatingen Phone 41 32 556 68 00 Fax 41 32 556 68 99 into montratec com www montratec com 508978 06 10 e
14. 6 4 5 TracLink tabletop MONTRAC 71 Ref No 54819 Ref No 57431 72 MONTRAC MONTRAC 73 QS FRAMEWORK 1 FOOT SUPPORT TRAC QS FRAMEWORK 2 FOOT SUPPORT TRAC TRAC PO cN N N LO N LO Te 560 900 mm to top edge e amp of shuttle pallet foot support 1565 with floor anchor bracket FW 900 mm to top edge of shuttle pallet 2 foot support with FW Trac Trac 91569 QS FRAMEWORK 1 SUPPORT TRACLINK QS FRAMEWORK 2 FOOT SUPPORT TRACLINK TRACLINK 90 LO lt F 45 602 900 mm to top edge of shuttle pallet RN 2 foot support with FW 58298 of shuttle pallet 1 foot support with FW for TracLink 56817 74 MONTRAC MONTRAC 75 QS FRAMEWORK 2 FOOT SUPPORT QS FRAMEWORK 4 FOOT SUPPORT p N 652 626 900 mm to top edge of shuttle pallet 560 900 mm to top edge of shuttle pallet x 2 foot support with FW TracLink to Trac 58299 Re No 4 foot support with FW 58301 QS FRAMEWORK 3 FOOT SUPPORT TO TRACLINK for long sections QS FRAMEWORK SUPPORT FOR ERGOTRAC 8i w ill Ln zai T aj N E 2 A i PSII Sse poe ft Le g 504 9 NI
15. 77 1 60 1 65 123 201 2 8 21 2 8 2 8 2 2 8 29 21 1 65 1275 15727 79 1 63 1 69 130 2 7 2 8 2 7 2 8 2 8 2 9 2 8 2 9 240 1 0 15026 1 80 1 82 1 66 122 135 21 2 9 29 3 0 25 3 0 250 72 1 79 1 83 1 85 1 69 Jug 140 2 8 2 9 2 9 3 0 2 9 3 0 260 1 76 1 83 1 86 1 88 1252 1 8 145 2 8 2 9 2 3 0 2 3 0 270 1 79 1 86 1 86 1 91 1 79 1 84 150 2 8 3 0 20 3 1 2 9 3 0 280 1 82 1657 L E23 1 78 1 88 185 29 20 3 0 3 1 DAT 3 0 290 1 86 1572 1225 1 96 1 8 1 22 160 2 9 3 0 3 0 3 1 3 0 3 1 300 1 89 1 95 26 1779 1 84 165 28 3 0 3 0 35 210 3 1 Time measurement From the start command of the control device up to the presence signal of the control device in the positioning unit 170 2 9 3 0 3 3 2 0 3 1 without locking time and unlocking time 175 29 30 31 31 30 31 180 3 0 3 0 3 1 3 2 3 0 3 1 Time measurement From the start command of the control device up to the presence signal of the control device in the positioning unit without locking time and unlocking time 68 MONTRAC MONTRAC 69 TRACDOOR TRACDOOR TYPE OVERVIEW The TracDoor makes it possible to pass through a Montrac line The direction of the opening and or access workstations within the line mining por It has its own frameworks these have can be freely selected to be ordered separately They are available in various sizes single and dual sided for a person or a small forklift The TracDoor opens horizon tally like a gate and can be locked unlocked and op
16. MODULE DIMENSIONAL DRAWING The IRM Intelligent Routing Module and ISM Intelligent Shuttle Module are communication modules for exchanging data between Shuttles Trac elements and the control 102 system The ISM is included with the Shuttle and communicates between Shuttle and Trac a li Intelligent Routing Module IRM Bosic 56936 with AB cam and A com Basic Kit IRM 56937 Box single cable for supply Curve Kit IRM 56938 Proximity switch holder box single cable for supply The ISM Shuttle module commu nicates with various IRM Trac mod ules via infrared signals The IRM Trac module can autono mously control a TracSwitch Trac Crossing or TracCurve It also provides a communication interface between the Trac and your control ax o H So lt system Double Module Kit IRM Proximity switch holder The communication between your control system and an IRM takes box double cable for supply Double Sensor Kit IRM 2x Proximity switch holder place either via pre defined connec tor pins or by means of the serial interface on the IRM box double cable for supply explanations see page 15 CONTROL CAMS DIMENSIONAL DRAWING Travel direction U INTELLIGENT ROUTING MODULE TECHNICAL DATA Voltage supply VDC rated voltage 24 18 30 VDC Current consumption mA 25 at 24 VDC
17. and 400 56952 73 MINIMAL TRAC LENGTH SUPOTRAC 300 550 400 850 550 1300 MONTRAC 2 60 MONTRAC POSITIONING UNIT 2 3 The Positioning Unit positions pallets precisely 02 mm and or pro vides additional support for process es There are versions for single and multiple positioning Both versions are available in various sizes corre sponding to the standard platform dimensions POSITIONING UNIT 2 3 TECHNICAL DATA pneumatic Positioning Unit for pallet length Weight Positioning horizontal plane x and y direction vertical plane z direction Drive medium Ambient conditions temperature rel humidity air purity kg mm mm PC 300 mm single 11 6 300 mm 400mm 400mm 550mm 550 mm multiple single multiple single multiple 12 6 12 8 14 7 14 16 8 DOO E 0 08 02 02 O 2 E 02 5 um filtered oiled or unoiled 10 to 40 5 85 without condensation normal workshop atmosphere POSITIONING UNIT SINGLE EPV DIMENSIONAL DRAWING Pallet length 300 mm 400 mm 550 mm A 04 MONTRAC 61 62 MONTRAC PERMITTED FORCES AND TORQUES ON THE SHUTTLE PALLET IN THE POSITIONING UNIT Rated pressure 5 bar aluminum pallet sealed in PV Mxadm single positioning multiple positioning MYadm single positioning multipl
18. with pallet alum cycle time with pallet cycle time with pallet cycle time with pallet axle empty cycle time time with pallet payload payload payload alum payload alum payload alum payload with pallet alum payload alum payload step size b mm without s max s without s max s without s max s distance a mm without s max s without s max s without s max s without s max s without s max s 100 1 44 1 45 124 1 43 1 47 1 49 55 2 20 2 4 27 2 4 2 5 2 4 2 5 24 25 105 1 44 1 46 1 44 1 44 1 47 1 50 60 21 2 4 2 4 2 4 2 5 2 5 2 4 2 5 2 4 2 5 110 1 44 1 47 1 45 1 46 1 47 1590 65 2 2 4 2 4 2 4 2 5 25 25 26 255 2 6 115 1 45 1 48 1 46 1 47 1 47 1 50 70 2 4 2 5 2 4 2 5 2 5 2 5 2 5 20 2 5 2 6 120 1 45 1 49 1 47 1 48 2 75 2 4 25 2 5 25 25 2 6 25 2 6 25 20 130 1 46 1 51 1 49 1 51 1 48 1 51 80 2 5 2 5 2 5 2 6 2 2 6 2 6 2 7 2 6 2 7 140 1 47 592 52 1 48 57 85 20 2 6 2 5 2 6 2 6 2 6 2 6 D 2 6 2 7 150 1 48 1 54 1 54 1 5 1 48 1 52 90 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 7 2 6 2 7 160 1 48 1508 1656 1 58 1 49 1 53 25 2 6 2 6 2 6 27 20 2 7 2 7 2 8 2 7 2 8 170 1 50 1 57 1 58 1 61 1 49 1 54 100 2 6 2 7 2 7 2 6 2 7 2 7 2 8 2 7 2 8 180 lesa 6 1 60 1 63 1 49 1 54 105 2 6 21 2 6 27 21 2 8 21 2 8 190 1 57 1 61 1 62 1 66 1 50 1798 110 24 2 7 2 6 24 2 8 2 8 24 2 8 200 158 862 169 1 68 120 1555 115 2 7 2 8 2 7 201 2 8 2 2 8 2 210 1 57 1 67 1 70 1 74 1 58 1 61 120 2d 2 8 2 7 2 8 2 8 2 9 2 8 2 9 220 1 62 1 70 1 74
19. 0 vertical switch cabinet D 500 42 25 IP 10 vertical switch cabinet 1 15 10 to 50 humidity class F without cond with rel humidity of 85 normal workshop atmosphere MONTRAC 43 SWITCH CABINET TO LIFT CHAOS TECHNOLOGY LCT TECHNICAL DATA Rated current Rated power Protective class Installation type Weight Measurements H x W x D VAC W kg mm SWITCH CABINET LCT DIMENSIONAL DRAWING 600 397 791017 800 IP 2 vertical 22 600 380 350 cabinet LCT Version 1 2 3 Level 58558 Version 1 4 7 Level 58560 44 MONTRAC FASTENING TO SWITCH CABINET LCT 545 SLL 55 40 SP 64D 40 DEK 40 DP 40 L 600 397 Slot insert 4 kt M8 to switch cabinet LCT 59620 ACCESSORIES LIFT Description Complete connecting Trac R Complete connecting Trac L Fall guard Box for fall guard Stop Trac with damping IRM Basic with Y cable AB cam and A cam A and AB cam set Motor line Return system line Cable tor measurement system 7 wire supply cable for 24 VDC Supply voltage servo regulator connection and external control 2 wire supply cable for Trac power supply Control set for lift see operating instruction control set BA 100092 Switch cabinet Lift LCT Chaos Technology variante 1 2 3 level see operating instruction switch cabinet BA 100091
20. 55 ms 6 2 kg 54 MONTRAC 55 PALLET TWO AXLE SHUTTLE 3 LOAD LIMITS The pallets fit on top of the Shuttle and are the platform on which your parts rest The pallets are available in various sizes between 200 x 300 mm and 300 x 550 mm The number and location of the positioning prisms is a customer specific choice EM NEM HES 4 payload 34 kg ms mp mp pallet weight see table page 55 Scope of delivery Includes the 4 inserts that mate to the Shuttle The milling for positioning prisms ms 9 kg and special tooling should be done by the customer The production drawing for milling the pallets for the prisms can be found on our website at www mon tratec com support service forms If requested the prisms can also be set by montratec AG PALLET TECHNICAL DATA Pallet weight 200 mm x 300 mm kg 22 200 mm 400 mm kg di 300 mm x 400 mm kg 5 0 200 mm x 550 mm kg 4 6 300 mm x 550 mm kg 6 9 56 MONTRAC MONTRAC 57 SUPOTRAC ERGOTRAC PALLET DIMENSIONAL DRAWING The SupoTrac serves os a product support at machining stations to prevent the shuttle from being influ enced by outside forces It is not suitable for stations with press opera tions T The SupoTrac makes claims Sleeve inserts concerning ergonomics or satety regulations for manual workstations Pallet max number Supofrac is fasten
21. 9 1512 1 10 1 15 ae 1 45 Two Axle Shuttle 3 rear axle empty cycle time with pallet alum without s 0 81 0 83 0 84 0 86 0 87 0 89 0 90 0 92 0 93 0 95 0 96 0 98 0 99 1 01 1 02 1 04 1 05 1 07 1 08 1 10 1 11 1 14 1 16 1 42 payload max s 0 85 0 8 0 88 0 90 0 9 0 93 0 94 0 96 0 97 0 99 1 01 1 02 1 04 1 05 107 1 09 1 12 IIS 1 16 1 18 1 20 1 2 1 42 MONTRAC Two Axle Shuttle 3 cycle time with pallet alum without s 0 78 0 80 0 81 0 82 0 84 0 85 0 8 0 88 0 89 0 90 0572 0 93 0 94 0 96 0 97 0 98 1 00 1 01 1172 1 04 1 05 1 06 1 08 1412 1 47 Time measurement From the start command of the control device up to the presence signal of the control device in the positioning unit without locking time and unlocking time payload max 8 0 82 0 84 0 85 0 87 0 88 0 90 0 91 0 93 0 94 0 95 0 97 0 98 1 00 1 01 1 03 1 04 1 06 1 07 1 09 1 10 112 leks 1 15 1 16 1 49 65 66 MONTRAC MONTRAC 67 Travel direction Travel direction CYCLE TIME b IN THE POSITIONING UNIT MULTIPLE MPV continuation CYCLE TIME d IN THE POSITIONING UNIT MULTIPLE MPV Shuttle 3 Two Axle Shuttle 3 rear axle empty Two Axle Shuttle 3 Shuttle 3 200 x 300 Shuttle 3 300 x 400 Shuttle 3 200 x 550 Two Axle Shuttle 3 rear Two Axle Shuttle cycle time with pallet alum cycle time with pallet alum cycle time
22. HPANEL The TouchPanel can be mounted in any position Mounting is performed using Quick Set fastening ele ments on the dovetail on the rear side 85 86 MONTRAC MONTRAC 87 LOGIBOX LOGIBOX DIMENSIONAL DRAWING The LogiBox is a small control unit with eight digital inputs and eight digital outputs In addition two IRMs can be read and written via the RS 232 interfaces The LogiBox continues with the idea of chaos technology For example the LogiBox can control a dual switch Other project specific solu tions can also be realized The number type and position of the screwed cable glands are project specific and determined by the project manager FASTENING SUGGESTION FOR LOGIBOX The LogiBox can be mounted in any position Mounting is by means of Quick Set fastening elements on the dovetail on the rear side LOGIBOX TECHNICAL DATA Weight kg 0 6 Input voltage VDC 24 Current consumption at 24 VDC mA 50 without Outputs Min input voltage Inputs VDC 20 Max input voltage Inputs VDC 28 Current consumption per Input mA 5 Output voltage Outputs VDC input voltage Max output voltage per Output mA 500 Material aluminium nickel plated copper steel brass plastic Protective class IP 20 Ambient conditions temperature j 10 to 40 rel humidity 5 85 without condensation air purity normal workshop atmosphere 88 MONTRAC POWER SUPPLY The ele
23. IRM list includes the required IRM kits and functions in the correct sequence LIBRARY WITH PRECONFICURED SECTIONS The library provides commonly used preconfigured layout sections including Trac peripheries and associated framework These elements can be inserted into the configuration as complete assemblies by dragging amp dropping them Custom configurations can be added to the existing library MONTRAC 13 Fro eg re an z dia Vp eS p lt s 1 P QbEBGxsTS DARI I P grs murio am cum Fm amer uc pum DU r uie Px ud c Wes 14 MONTRAC TRAVEL CONTROL WITH IRM amp ISM The IRM amp ISM Intelligent Routing Modules amp Intelligent Shuttle Mod ules are used to control the Trac and Shuttles in a Montrac system The IRM and ISM are infrared com munication modules that exchange data allowing Shuttle Trac and work station to interact The ISM Shuttle module and IRM Trac module communicate with each other In addition to communicating with the ISM the IRM can also control TracSwitchs and Crossings when programmed to operate auton omously CONTROLLING THE TRAVEL SPEED The speed of the Shuttle is controlled by IRM and control cams positioned along the Trac The IRM gives the start command which accelerates the Shuttle
24. Max load current A 1 at 24 VDC outputs short circuit proof 4021 0211 2 identical proved 10 wire JST plugs EUER Jj C x RS232 onnections 3 DIN 3 x DOT Temperature operation ES 10 to 70 storage transport 30 to 80 Dimensions mm 102 x 36x 11 length x width x height Assembly gauge Art Nr 22008 Weight g 23 84 MONTRAC TOUCHPANEL The TouchPonel is an input device used to equip manual workstations The operator uses the intuitive touch screen to enter the next station to be approached The principle is based on chaos technology The TouchPanel with digital IOs can also be used as a small control unit TOUCHPANEL TECHNICAL DATA Weight Input voltage Current consumption at 24 VDC Min input voltage Inputs Max input voltage Inputs Current consumption per Input Output voltage Outputs Max output voltage per Output Material Protective class Ambient conditions temperature rel humidity air purity kg VDC mA VDC VDC mA VDC mA PC TouchPanel without IO s TouchPanel with O s 1 7 1 7 2 24 165 165 20 _ 28 5 E input voltage 500 oluminium nickel ploted copper steel plostic rubber IP 40 10 to 40 5 85 without condesation normal workshop atmosphere TOUCHPANEL DIMENSIONAL DRAWING TouchPanel without IO s 58282 TouchPanel with IO s 8 Inputs 8 Outputs 58229 MONTRAC FASTENING SUGGESTION FOR TOUC
25. Switch cabinet Lift LCT Chaos Technology variante 2 4 7 level see operating instruction switch cabinet BA 100091 Operating module Keypad XT min 1 piece per lift PC system USB bus adapter if customer requires Profibus Bus module if customer requires PC system bus adapter RS 232 if customer requires Mounting bracket for wall Monting bracket for QS Frame QS Framework for Litt Options 5 meter 10 meter 20 meter 5 meter 10 meter 20 meter 10 meter 15 meter 20 meter 10 meter 15 meter 20 meter 10 meter 15 meter 20 meter MONTRAC 45 Ref No 57463 57457 59422 57644 57629 57958 56936 90759 520319 520320 520921 220322 520323 520324 57470 57614 5 615 520360 1 0000 520360 1 5000 520360 25000 520361 10000 520361 15000 52036 1 25000 58562 58558 58560 520325 320826 520445 520393 27710 5791 57912 46 MONTRAC MONTRAC 47 DIMENSIONAL DIAGRAM OF LIFT IN A 55 SHUTTLE 300 DIMENSIONAL DIAGRAM OF LIFT IN A IRACSWITCH SHUTTLE 300 min 627 min 582 min 582 or Complete conn Trac R 5 463 Complete conn Trac L 5 457 IRM Basic with 56936 Y cable AB cam and A cam A cam and AB cam Set 90759 lt a Complete connecting Trac R 57463 Complete connecting Trac L 57457 IRM Basic 2 piece with 56936 Y cabl
26. ationTrac 300 IsolationTrac 660 Including DC DC converter 60508 DC DC converter separate 506859 190 90 MONTRAC MONTRAC 9 SPECIAL ACCESSORY RFID SHUTTLE FASTENING TO POWER SUPPLY With the RFID shuttle the transported DP 40 L 500 product not the shuttle as before determines the route through the Slot insert M6 transport system Attached to the product on the shuttle is a tag or transponder con taining an identification with the 460 route through the Montrac system The RFID shuttle provides added automation streamlining of the material flow RFID SHUTTLE TECHNICAL DATA Transponder labels of standard ISO 15693 Ambient conditions temperature C 10 to 40 rel humidity 5 85 without condensation air purity normal workshop atmosphere 92 MONTRAC MONTRAC 93 SPECIAL ACCESSORY SHUTTLE WITH ADDITIONAL POWER SUPPLY SPECIAL ACCESSORY SHUTTLE WITH CONVEYOR BELT 24V 3A can be available on the shuttle The 2 axle shuttle with empty A conveyor belt adapted to require ments is permanently mounted to the rear axle serves as the basis shuttle By means of an added power collec This means that each shuttle travels tor built into the rear axle the power with a loader and unloader and that can be used for the components on the shuttle some handling stations are no longer needed The shuttle with power supply has The power s
27. certain special conditions e g heavy product weight and or extremely high sensitivity to vibrations The radius of 280 mm 580 mm gives Montrac unparalleled flexibility 90 inside conductor rail 56095 90 outside conductor rail 56096 TRACCURVE 45 DIMENSIONAL DRAWING 2x TracCurve 90 2x TracCurve 90 R500 TRACCURVE TECHNICAL DATA 203 45 90 R500 45 R500 TracCurve weight kg 219 1 4 5 0 2 8 Material aluminium nickel plated copper plastic Rated voltage VDC 24 Current carrying capacity A 64 Ambient conditions temperature C 10 to 40 457 inside conductor rail rel humidity 5 85 without condensation 45 outside conductor rail air purity normal workshop atmosphere 24 MONTRAC MONTRAC 25 FREE SPACE FOR SHUTTLE WITH PALLET SIZE OF 200x300 300x400 IN A TRACCURVE 90 FREE SPACE FOR SHUTTLE WITH PALLET SIZE OF 200x400 200x550 300x550 IN A TRACCURVE 90 200x400 200x550 300x550 R350 R380 R410 A B F200 R300 R330 9 200x300 300x400 200x300 7 26 MONTRAC MONTRAC 27 TRACCURVE 90 R500 DIMENSIONAL DRAWING FREE SPACE FOR SHUTTLE IN A TRACCURVE 90 R500 Pallet Me on 200 400 200 550 300 400 300 550 B R450 8450 R500 R400 8450 D 295 295 295 381 3 9 BE TrocCurve 8500 T 90 R500 inside conductor rail 1 279 279 233
28. ctrical power supply unit mainly consists of a 24 VDC power supply short circuit protection and an emergency stop It is connected to the conductor rails on the Trac to power the Shuttles TracSwitches TracCrossings TracLocks IRMs and proximity switches POWER SUPPLY TECHNICAL DATA Input voltage Mains frequency Operating range Switch on current Input power at rated load Harmonic wave filter DC output voltage Control accuracy of output voltage DC output voltage at Output voltage ripple Current limitation adjustable 10 110 Temperature operation storage transport Humidity class according to DIN 40040 Cooling VAC Hz A kW C PC 40 A supply 24 axles 25 1523 60 A supply 2 x 40 A supply 36 axles 48 axles 3 x 400 202 380 500V 47 63Hz 222225 2125 1 7 2 9 integrated passive filter according to EN IEC 61000 3 2 40 200 44 24 28 8 adjustable 1 396 of set value 60 2x40 200 200 max 66 max 2 x 44 O to 50 25 to 85 F no condensation natural air cooling POWER SUPPLY UNIT WITH WALL CABINET 500 25 5 Switch disconnector kill switch VCFO2 XB4 BA42 ISOLATIONTRAC DIMENSIONAL DRAWING 131 115 190 MONTRAC 89 T mw Power supply unit 40A 60506 Power supply unit 60A 60507 Power supply unit 2x40A Use always with IsolationTrac Isol
29. ductivity is to streamline and automate your material flow While this is not always feasible with conventional conveyors the Montrac trans port system can help you implement your productivity objectives simply flexibly and profitably Let us be a part of your success get on the right Tracl CONTENTS MONTRAC 7 SOLUTION PATHS MONTRAC CONFIGURATOR CONTROL SYSTEM CHAOS TECHNOLOGY TRAC TRACLINK TRACCURVE TRACSWITCH TRACSWITCH ARENA TRACCROSSING LIFT SHUTTLE PALLET SUPOTRAC ERGOTRAC POSITIONING UNIT TRACDOOR FRAMEWORKS INTELLIGENT MODULES TOUCHPANEL LOGIBOX POWER SUPPLY SPECIAL COMPONENTS ACCESSORIES Modification reserved 14 16 18 20 22 28 32 36 Sm 2 60 68 70 82 84 86 88 9 27 8 MONTRAC SOLUTIONS FOR YOUR PRODUCTION SYSTEM Are you planning a new production system or expanding an existing pro duction facility The Montrac monorail system provides you with fast and flexible solutions Montrac is an intel ligent transport system networking industrial production and logistic processes Envision your production and logistics in the future Montrac can help you realize that vision today Montrac will revolutionize your logistic and produc tion workflow APPLICATION EXAMPLES Intra logistics and assembly line In one of the largest engine plants in the world production and logistics must be perfectly synchronized Space is a p
30. e AB cam and A cam Pallet Pallet size 400 mm 550 mm size 400 mm 550 mm D MO7 1537 B 2800 2560 2820 3080 IA B TT 2 l il Hi or Complete conn Trac R 57463 Complete conn Trac L 57457 2 Complete connecting Trac R 57463 Complete connecting Trac L 57457 IRM Basic 2 piece with 56936 Y cable AB cam and A cam IT gt d Mi al PT EX m IRM Basic with 56936 Y cable AB cam and A cam A cam and AB cam Set 90759 48 MONTRAC MONTRAC 49 COMPLETE CONNECTING TRAC L complete connecting trac R mirror inverted LIFT FASTENING TO A QUICK SET STRUCTURE max 500 min 230 min 300 131 EV 3 40 AK 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 Complete connecting Trac R 5 463 Complete connecting Trac L 57457 Monting bracket for QS Frame 57911 260 180 260 QS FRAMEWORK FOR LIFT without means of protection LIFT FASTENING TO A WALL max 500 min 230 BW 40 AK 66 40 SLL 55 40 LP 66 40 max 200 min 110
31. e a sign off of the shuttle for a falling signal from the sign off sensor For a sign off of the shuttle for a rising signal from the sign off sensor the values for L will need to be increased by 70 mm in each case Standard and 2 axle 2 axle Shuttle Shuttle rear axle 300x550 platform empty 300 x 550 alu platform alu 375 mm LU 375 mm payload payload without without 5 s 36 MONTRAC MONTRAC 37 TRACCROSSING TRACCROSSING DIMENSIONAL DRAWING The TracCrossing makes it possible for two lanes to intersect each other at a right angle and is powered directly from the conduc tor rails Delivery options 150 You can order the TracCrossing pre contigured for a specific task You can mount the conductor rails and configure the controller as required for your application The montratec Motor Configu rator software is available at www montratec com eRe No 58864 FREE SPACE FOR SHUTTLES WITH PALLET WIDTH 200 300 TRACCROSSING TECHNICAL DATA TracCrossing weight kg 12 Material aluminium nickel plated copper steel brass plastic Rated voltage VDC 24 1 x RS232 Connections 2 x DIN per used positions 1 x DIN 3 x DOT per used positions 1 x DOT 1 x Error Rotation angle 7 Rotation time 90 1 4 1 7 Current carrying capacity The clearance will ne
32. e positioning MZadm single positioning multiple positioning FXEadm single positioning multiple positioning FXEadm single positioning multiple positioning FYEadm single positioning multiple positioning FYEadm single positioning multiple positioning FZadm single positioning multiple positioning FZEadm single positioning multiple positioning Xmin 55 mm Ymin 25 mm Nm Nm Nm Nm Nm Nm N IN IN IN IN IN IN IN IN IN IN IN 200x 300 15 5 Pollet dimensions in mm 200x400 300x400 200550 300x550 9 5 5 9 3 4 5 22 5 5 10 5 10 5 1 2 1 6 2 5 23 5 5 8 13 13 18 11 23 5 5 135 135 149 135 135 lt 135 59 185 139 135 135 135 135 135 135 135 139 135 135 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 3000 3000 2000 3000 2000 3000 3000 2000 3000 2000 1000 400 1000 400 The specified values cause the Shuttle pallet to shift max 0 3 mm toward the force vector 500 150 1000 400 500 150 MINIMUM POSITIONING UNIT TRAC LENGTH 35270 MONTRAC 63 55299 200x400 mm multiple 1100 mm 55292 300x400 mm single 55294 300x550 mm multiple 1600 mm 64 MONTRAC CYCLE TIME OF THE SHUTTLE IN THE POSITIONING UNIT SINGLE EPV Travel direction CYCLE TIME d IN THE POSITIONING UNIT SINGLE EPV Pallets 200 x 300 mm c adhered by distance sensor s
33. ed for Chaos Technology react to the target address directing the Shuttle to the next station This occurs within the IRM and does not require external controls The address is simply the identification number Addresses are stored in the Shuttle and can be changed as required MONTRAC 17 18 MONTRAC TRAC The monorail is made of colorless anodized aluminum extrusion Along the inside of the Trac are the conductor rails and on outside are T slots to which control modules can be placed The conductor rails can also be outside and the control modules inside if needed The Trac is compatible with the Quick Set framework system TRAC TECHNICAL DATA Trac weight Cross sectional area Section modulus Wx Section modulus Wy Moment of inertia Jx Moment of inertia Jy Length allowance Torsion allowance Straightness tolerance Material Rated voltage Current carrying capacity Ambient conditions temperature rel humidity air purity kg m mmf cm cm cm mm mm m mm m VDC A PC Dus 1957 277 10 8 230 21 6 0 5 aluminium nickel ploted copper plastic 24 64 10 to 40 596 8596 without condensation normal workshop atmosphere TRAC DIMENSIONAL DRAWING View A MONTRAC 19 L 2960 mm 56926 2960 lengths between 60 56926 xxxx 2960 mm are available 1 mm step Guide profile conductor rail and cover profile are i
34. ed to an existing 4 sleeve inserts prisms Ret No Trac 200 300 15 mm Ergolracs replace a normal Trac i f 11 in length 200x400x15 mm piece of 1160 mm in leng 300x400x15 mm The ShuftleLock prevents the Shuttle from moving during manual opera 200x550x15 mm tions The ShuttleLock can be pow 300x550x15 mm ered directly from the conductor rails and is the included in the delivery of Special sizes on request Accessories for pallets Prism for pallets Prisms Sleeve insert set the Supolrac and ErgoTrac STANDARD DIMENSIONS Single pallet 200x300 mm Multiple pallet 200x300 mm max 6 prisms Single pallet 200x400 mm Single pallet 300x400 mm Multiple pallet 200x400 mm Multiple pallet 300x400 mm max 8 prisms Single pallet 200x550 mm Single pallet 300x550 mm Tilt angle 25 Multiple pollet 200x550 mm Multiple pollet 300x550 mm max 12 prisms Ambient conditions temperature C 10 to 40 rel humidity 5 85 without condensation air purity normal workshop atmosphere JUHU GY SUPOTRAC ERGOTRAC TECHNICAL DATA Supolrac Ergolrac Weight kg 3 4 8 58 MONTRAC SUPOTRAC DIMENSIONAL DRAWING m rji size L 200x550 300x550 SupoTrac with ShuttleLock for pallet width 200 and 300 56933 245 ERGOTRAC DIMENSIONAL DRAWING 280 599 280 183 223 ErgoTrac with ShuttleLock for pallet width 300
35. ed to be increased upward between the Trac connections 64 depending on the lood on the moveable Trac section A 238 Mechanical load capacity IN 340 Ambient conditions temperature 10 to 40 rel humidity 5 85 without condensation air purity normal workshop atmosphere corresponds to the weight of a fully laden two axel shuttle 38 MONTRAC MONTRAC 39 LIFT RUN TIMES TRACCROSSING The lift transports Shuttles vertically for the following tasks Connection of two or more systems AB Cam with different working heights Transport of Shuttles from a station to a ceiling system and vice versa 1 The measurements for L assume a sign off It is mandatory that safety guards be of the shuttle for a falling signal from the installed around the lift sign off sensor For a sign off of the shuttle for a rising signal from the sign off sensor the values for L will need to be increased by 70 mm in each case Standard Shuttle Standard Shuttle Standard and 2 axle 2 axle Shuttle 200x300 platform 300x400 platform Shuttle rear axle 300x550 platform alu alu empty 300 x 550 alu platform alu L 80 mm 180 mm LU 350 mm LU 350 mm payload payload payload payload without I without without without Passage at s s s s LIFT TECHNICAL DATA Weight basic structure kg s per additional meter kg 14 Min position of the Trac from ground mm 525 stroke
36. ened manually Included in the scope of delivery are two sign on and sign off sensors and a green warning lamp dg l HW 2 Framework 1 page 81 92064 TracDoor single L 2000 mm 56953 Framework 2 page 81 92066 3000 The direction of the opening 1055 can be freely select s rr r r rr lear width 1850 TRACDOOR TECHNICAL DATA Length tolerance of the TracDoor mm 2221 co Material aluminium nickel plated copper plastic m 19 1 Rated voltage VDC 24 T i Current carrying capocily i F between the Trac connections A 64 1 i l on the moveable Trac section 2 5 rel humidity 570 8576 without condensation TracDoor double L 3000 mm 56954 Framework 1 page 81 92064 air purity normal workshop atmosphere 70 MONTRAC QUICK SET FRAMEWORKS Quick Set is o speciolly designed framework system that easily attaches to all montratec components includ ing Montrac The frameworks are modular designed the same as the travel section QUICK SET FRAMEWORKS TECHNICAL DATA Material Ambient conditions temperature C rel humidity air purity aluminium nickel plated copper steel brass plastic 10 to 40 596 8596 without condensation normal workshop atmosphere QS FRAMEWORK FOR TRAC TABLETOP QS FRAMEWORK FOR TRACLINK TABLETOP 64 SP 64E 40 08 4
37. h stopping point in the system At the minimum it serves to detect and start the Shuttles The IRM Basic assembly serves this purpose It consists of an IRM a connection cable an AB cam speed reduction and an A cam stop Various connection kits are available for specific uses connection box terminal box for a single IRM with or without proximity switch holder connection box for two IRMs and a proximity switch holder and connection box for an IRM and two proximity switch holders MONTRAC 15 16 MONTRAC 5 TECHNOLOGY Chaos Technology is a means of allowing the Shuttles to navigate a Montrac system without external controls It originated from the concept of allowing each decision making point to operate independently and coordi nating them by storing information on the Shuttle By allowing Chaos Technology to focus on logistic decisions more attention can be given to optimizing the processes within the stations CHAOS TECHNOLOGY COMPONENTS The IRM and ISM explained on page 10 are used to control the Trac and Shuttles with Chaos Technology On the most basic level The ISM and IRM as part presence detectors and start switches The ISM residing in the Shuttle sends an in position output to the IRM attached to the Trac each time the Shuttle comes to a stop This is then passed along via discrete I O to your PLC Once the work is complete your controller sends a discrete signa
38. hed Shutle 3 300 400 500 a LC 30 12 17 3 8 4 1 4 6 lt 2 24 0 08 0 80 2 24 0 85 1 40 5 85 without condensation normal workshop atmosphere Two Axle Shuttle 3 rear axle empty 550 30 12 17 6 2 24 0 08 0 80 2 24 0 85 1 40 lt 59 10 to 40 MONTRAC Two Axle Shuttle 3 550 0 30 12 34 7 ew 24 0 16 1 16 4 48 0 80 12 5 22 MONTRAC SHUTTLE 3 DIMENSIONAL DRAWING 200 300 165 9 300 400 550 20 170 270 420 TWO AXLE SHUTTLE 3 DIMENSIONAL DRAWING 200 300 165 ls MONZNEGH ol je of GU for pallet length 400 mm U tor pallet length 550 mm GU for pallet length 550 mm Other Shuttle length on request Two Axle Shuttle 3 U rear axle empty GU rear axle empty Other Shuttle length on request Ret No 54793 54794 54795 54796 54797 54798 Ref No SHUTTLE 3 LOAD LIMITS e MONKNECH e pn PTI TY TV v LL LLA LA TWO AXLE SHUTTLE 3 REAR AXLE EMPTY LOAD LIMITS NEM NEM NM Bs EN o MONKNEGH o MONTRAC 53 mn payload 17 kg ms mp transported parts including their carriers on the pallet mp pallet weight see table page 55 ms Shuttle weight see table page 51 mn payload 17 kg ms mp mp pallet weight see table page
39. l to the IRM and it passes the start command to the ISM ADDRESSING THE COMPONENTS In addition to detect and start IRM and ISM can send and receive identification numbers group and 10 that are saved in the Shuttle When the Shuttle comes to a stop the ISM sends the in position output along with the stored identification numbers The IRMs uses this information internally to autono mous control of TracSwitches At work stations the information can be passed on to your controller via the serial connection DECOUPLING TRAC AND PROCESSES The Montrac system is the logical connection between process stations Chaos Technology uses rules direct traffic in a way that supplies stations with goods in an optimum fashion With Chaos Technology the Trac components can operate autonomously inter action with the coordinating control system occurs exclusively in the process stations Upon leaving a process station the Shuttle is assigned identification numbers based on the product s status which in turn defines the next process step The Trac is controlled autonomously using these identifi cation numbers THE PRODUCT CONTROLS THE TRAC All process stations are numbered e g consecutively These numbers are target addresses corresponding to the stations to which the Shuttles are traveling The principle of Chaos Technology is that upon completion of a process the Shuttle is given the next target address All actuators configur
40. ll as to verify processes in assembly systems SCALES MODULE TECHNICAL DATA Rated voltage IVDC Ambient conditions temperature C rel humidity air purity MONTRAC v9 24 10 to 40 596 8596 without condensation normal workshop atmosphere 96 MONTRAC MONTRAC 97 SPECIAL ACCESSORY SHUTTLE FOR HEAVY LOADS ACCESSORIES For loads up to 50 kg a so called ACCESSORIES FOR TRACSWITCH AND TRACCROSSING heavy weight shuttle has been devel oped The new shuttle has reinforced Ref No carriage and profiles and runs at Configuration by montratec 56935 controlled speed CPC connection cable 506157 Flag for TracSwitch 57456 The latest montratec Motor Configurator software version is available at www montratec com ACCESSORIES FOR POSITIONING UNIT PV 2 3 Ref No Adjustment gauge B 200 mm 55386 Adjustment gauge B 300 mm 55387 Precision spirit level L 200 mm 506339 ACCESSORY STOP START CONTROL ELEMENT Ref No Holder for signal transmitter 45428 Straight A cam 47200 Curved A cam for outside T groove 47201 Curved A cam for inside T groove 90822 Curved A cam R500 for outside T groove 58646 Curved A cam R500 for inside T groove 58644 Complete A cam L 21 44 mm 90730 21 44 B cam 45314 AB cam 45315 A and AB cam set 90759 Curved A and AB cam set for outside T groove 91516 Curved A and AB cam set for inside T groove 91517 Curved A and AB cam set R500 for outside T g
41. ller as required for your application The montratec Motor Configu rator software is available at www montratec com TRACSWITCH ARENA TECHNICAL DATA TracSwitch Arena weight Material Rated voltage Connections Rotation angle Rotation time 60 150 210 Current carrying capacity between the Trac connections on the moveable Trac section Mechanical load capacity Ambient conditions temperature rel humidity air purity corresponds to the weight of a fully laden two axel shuttle kg VDC sec N e Bes aluminium nickel plated copper steel brass plastic 24 x R5232 3 DIN per used positions 1 x DIN 4 DOT per used positions x DOT 1 x Error 60 150 210 60 0 5s 150 1s 210 1 5s 64 2 9 340 10 to 40 596 8596 without condensation normal workshop atmosphere MONTRAC 33 TRACSWITCH ARENA DIMENSIONAL DRAWING Free space Free space 150 mm 150 mm 465 3 537 3 Re No TracSwitch Arena 58879 OVERVIEW TRACSWITCH ARENA POSITIONS AND TYPES Position Position 2 Position 3 TracSwitch Arena L Pos 1 4 The desired TracSwitch Arena type can be configured with the montratec Motor Configurator software The latest version is available at www montratec com Pos 4 is equal to Pos 1 360 turned 34 MONTRAC FREE SPACE FOR SHUTTLES WITH PALLET SIZE OF 200x300 200x400
42. m reduces air turbulence The standard components were designed for a class 1000 cleanroom With minor adjustments we have reached class 100 according to US Federal standard 209E MONTRAC 9 10 I MONTRAC PROFITABILITY amp COST EFFICIENCY Montrac s latest developments are 300 000 Eure aimed at increasing the system s efficiency M 260000 Montrac is driven solely by electricity Cumulative costs conveyor system there are no costly pneumatic Cumulative costs Montrac components or connectors 200000 Power is supplied directly through the conductor rails this means there is very little to no cabling required With Chaos Technology program ming and controls hardware is reduced or eliminated 106 onn Cost comparison over 6 years Conventional conveyor system with m 34 motors 11 stations and 48 pm pallets Montrac with 24 Shuttles and 11 pro cess stations z FE i b amp 2 x m 1 Implementation costs 2 Investment in the system 3 Maintenance costs Project planning Conveyor belt 100 000 Euro Conveyor belt Montrac Wirin ras maintenance 4 000 Euro 400 Euro Assembly Montrac 124 000 Euro electricity 15000 Euro 750 Euro Software pneumatic system 1 667 Euro 83 Euro total 1 year 20 667 Euro 1233 Euro total 6 years 124000 Euro 7400 Euro Conveyor belt Montrac Initial investme
43. ncluded in the scope of delivery View B 20 MONTRAC TRACLINK The TracLink is the connecting ele ment between two Trac sections or between Trac and active compo nents This element provides the electrical connection for the conduc tor rails and allows for thermal expansion The TracLink also pro vides the electric connection between elements An internal 100k ohm resistor is built into the circuit between the Trac components Trac TracLink TracCurve etc and ground ESD TRACLINK TECHNICAL DATA TracLink weight Material Rated voltage Current carrying capacity Ambient conditions temperature rel humidity air purity kg VDC PC 0 25 aluminium nickel plated copper plastic 24 64 10 to 40 596 8596 without condensation normal workshop atmosphere TRACLINK DIMENSIONAL DRAWING MONTRAC 21 Wadiki 40mm 57949 TracLink L 40 mm for the power supply TRACEND DIMENSIONAL DRAWING Termination piece for open section Ref No 56788 22 MONTRAC MONTRAC 23 TRACCURVE TRACCURVE 90 DIMENSIONAL DRAWING Curved Trac elements are available in 90 or 45 There is no impact on Shuttles when traveling through a TracCurve The 115 cross section of TracCurve is identical to the Trac A 180 curve can be arranged using two 90 TracCurves The TracCurve R500 is used under
44. nt 100 000 Euro 124 000 Euro 24 Implementation 60 000 Euro 20000 Euro 66 Service and maintenance over 124 000 Euro 7400 Euro 94 Total cost 284 000 Euro 151 000 Euro 46 96 This cost comparison was conducted by a customer MONTRAC FOR A CLEANER ENVIRONMENT Montrac is not only attractively priced it is also environmentally friendly A conveyor belt system with 34 motors consumes 20 000 worth of electricity a year whereas a comparable Montrac system only consumes 600 This equates to a significant reduction in environmental impact An analogy using automobiles illustrates this point from a different perspective a Montrac Shuttle would be able to travel more than once around the world estimated distance of 26 600 km using only two tanks of fuel Conveyor belt MONTRAC Montrac 11 12 MONTRAC INTERACTIVE MONTRAC CONFIGURATOR Using our free configuration tool you can contigure Montrac systems yourself and experiment with different layouts This tool lets you easily adapt the path of the monorail to your facility to create the perfect solution for your specific needs and spatial restrictions Your floor plan can be imported in 2D or 3D DWG or DXF The intuitive construction handles make it easy to design systems The required control elements IRMs amp proximity switches can be added with the click of a mouse You can toggle between 2D and 3D views for a choice of layou
45. ods The Trac itself is a passive element and not subject to failure The Shuttles and switches are the only active components in your system and they were designed to be virtually maintenance tree SIMPLICITY Montrac was designed to be extraordinarily simple It is comprised of very few components making design and assembly very easy compared to ordinary con veyor systems The Trac components are quick to assemble Other than a straight cut there are no machining processes required The exclu sive use of electronic components eliminates the need for pneumatic connections and complicated wiring Chaos Technology greatly reduces cabling and program ming You will benefit from this simplicity not only during assembly but also when changing or expanding your conveying system FLEXIBILITY Your needs are our primary focus We designed Montrac to be flexible enough to implement tomorrow s conveyance needs today All Montrac components have the same basic design and are compatible with each other So what you install now to meet today s needs can be reused tomorrow to meet future needs The bypasses switches and curves are compact to fit in tight spaces and maneuver around obstacles Montrac is flexible in ways that conventional conveyors could never be CLEANROOM Montrac is perfectly suited for cleanrooms The shuttles are self propelled and therefore have no dirty belts There is no sliding friction to create particulate Even its for
46. remium and every square meter has to be opti mized The pistons are manufactured several hundred meters from final assembly Montrac serves as both the transport system in the assembly line and as a fully automated delivery system to the final assembly area For this application Mon trac was by far the least expensive and most effective solution Connecting injection molding machines and other machines One of the most successful manufacturers of headlights uses Montrac for connecting its injection molding machines to the protective coating process Thanks to the completely antistatic properties cleanliness unparalleled flexibility of Montrac the system paid for itself in less than 18 months Testing while traveling A prominent manufacturer of tachometers uses Montrac in assembly Each cluster has to go through a test station in the assembly line Montrac makes it possible to start up the software and perform the testing during travel thanks to the additional 24 VDC electrical power supply on the Shuttle The manufacturer was able to cut costs by eliminating several cost intensive test stations RELIABILITY Montrac is the most reliable system available for transporting your products Traditional conveyors heavy wear items like belts and chains are single points of failure Since a Shuttle can be easily removed from the production process without stopping the system there is no production downtime when Montrac is transport ing your go
47. roove 58647 Curved A and AB cam set R500 for inside T groove 58648 Complete AB cam for TracCurve 91045 Electric switchable cam off currentless retracded for Shuttle visible 57023 Electric switchable cam on currentless extended for Shuttle invisible 57024 SHUTTLE FOR HEAVY LOADS TECHNICAL DATA AB and A cam flag 57020 Rated voltage VDC 24 AB cam flag 58183 Ambient conditions temperature C 10 to 40 flag 58184 rel humidity 596 8596 without condensation A cam flag for PV U 57008 air purity normal workshop atmosphere A cam flag for PV GU 57442 98 MONTRAC MONTRAC 99 ACCESSORIES FOR IRM ACCESSORIES Ref No Ref No IRM Configuration by montratec 56944 Proximity switch 26 5 mm PNP pluggable 508843 Contiguration device IRM 58693 Proximity switch M8 PNP pluggable 508845 Assembly gauge 92008 Proximity switch 26 5 mm PNP with cable 508842 The latest IRM ISM Configurator software version is available at www montratec com 5m connecting cable with straight plug 9 504610 5m connecting cable with angled plug M8x1 504929 SMC cylinder switch including fastening pluggable 505509 Festo cylinder switch including fastening pluggable 506885 Ref No D M9PZ cylinder switch with cable 5m PV 2 3 506879 Cable for IRM box power supply 57184 Box Single 56984 Cable for Supply 10 m 57577 Box Double 56985 Cable for Supply 30 m 57578 PC connection cable 57579 The IRM can be configured using the
48. t views There is also an integrated user s manual Natu rally it allows you to generate a bill of materials as well Interested Visit www montratec com for a closer look 3D CONFIGURATION The screen is divided into a vertical menu bar a large configuration window and a function and selection view The configuration window is where you configure the Montrac system in real time The resulting system is shown as a realistic 3D rendering or as a bill of materials Simple spatial elements can be used to simulate an existing building element for planning purposes Zones can be created where layouts can then be placed and referenced The user s manual is available in the upper toolbar CONSTRUCTION HANDLES The Montrac components are accessible from a hierarchical dropdown menu and can be dragged into the configuration window You can also double click on a piece of Trac to reveal the construction handle The constructions handle is comprised of several small icons that represent straight Trac TracCurves and TracSwitches Clicking on one of these icons drops in the next Trac section Conflicts in the configuration are displayed in real time and the user is given solution options AUTOMATIC PLACEMENT OF CONTROL ELEMENTS Intelligent Routing Modules IRM and the holders for proximity sensors can be positioned automatically with the click of two buttons The offer view displays the bill of materials including item numbers The
49. to the maximum speed of 30 m min There are three control cams that can be attached to the Trac to Decrease the speed to 12 m min AB cam Accelerate to 30 m min B cam or Bring the Shuttle to a stop A cam INTERFACES There are three types of electrical connectors on the IRM Voltage supply 24 VDC Digital inputs and outputs that are configured to specific functions e g start Shuttle detect Shuttle lock Shuttle sign off for conventional operation with external control and or for IRM logic functions including Chaos Technology RS232 serial interface communication interface for reading and writing Shuttle identification numbers group and ID Shuttle control in networked systems status indication visualization and more MONTRATEC IRM amp ISM CONFIGURATION SOFTWARE The Montrac Configurator can automatically determine and generate a list of IRM and corresponding kits required The montratec IRM ISM Con figurator software assigns and parameterizes specific functions module types to the IRM There are 14 module types that are available from a drop down menu The range of functions includes everything from curve monitoring to autonomous actuation of TracSwitches TracCrossings and ShuttleLocks This software can also be used to read and re write Shuttle identification numbers The latest version is available at www montratec com CONNECTION BOXES AND CABLES An IRM is needed at eac
50. upply of the conveyor many applications in various sectors belt is provided directly by the shuttle for example for autonomous loading 24V 34 and unloading of the shuttle with conveyor belt SHUTTLE WITH ADDITIONAL POWER SUPPLY TECHNICAL DATA Rated voltage 24 SHUTTLE WITH CONVEYOR BELI TECHNICAL DATA Rated current 3 Rated voltage VDC 24 Ambient conditions temperature FC 10 to 40 Ambient conditions temperature C 10 to 40 rel humidity 5 85 without condensation rel humidity 596 8596 without condensation air purity normal workshop atmosphere air purity normal workshop atmosphere 94 MONTRAC SPECIAL ACCESSORY FLEXTRAC With the FlexTrac Montrac can manage certain height differences e g between machines and process ing stations without having to use an elevator Depending on the application different incline angles are possible id TN _ mmm 1 FLEXTRAC TECHNICAL DATA Rated voltage IVDC 24 Ambient conditions temperature 10 40 rel humidity 5 85 without condensation air purity normal workshop atmosphere SPECIAL ACCESSORY SCALE MODULE montratec AG has developed a Supolrac with a built in high preci sion scale from the Eilersen company As the Shuttle drives in the SupoTrac the pallets are lifted and weighed with accuracy to within 1 10 gram no impact or vibration This mod ule is used in intralogistic applica tions as we
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