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M o n t r a c Design Guide

1. TRACCONTROL 1 IRM ACCESSORIES SPECIFICATIONS BOX SINGLE MT56984 TRACCONTROL 1 IRM ACCESSORIES SPECIFICATIONS BOX DOUBLE MT56985 Net weight g 160 Net weight g 320 Max cable cross section mm 0 5 Max cable cross section mm 0 5 Max cable diameter mm 5 Max cable diameter mm 7 Max voltage V DC 24 Max voltage DC 24 Max current A 2 Max current A 2 Ambiance Temperature 10 to 40 Ambiance Temperature 10 to 40 Rel Air humidity 5 96 85 96 without condensation Rel Air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Air purity level normal workshop ambiance ACCESSORIES FOR BOX SINGLE MT56984 ACCESSORIES FOR BOX DOUBLE MT56984 Part no Part no Cable for TC1 IRM Box supply MT57184 Cable for TC1 IRM Box supply MT57184 PC connection cable MT57579 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 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 Configurator software can be downloaded from the website www schmid group com The latest version of the TC1 IRM ISM Configurator software can be downloaded from the website www schmid group com 92 MONTRAC CCESSORIES FOR TRACCONTROL 1 IRM CONFIGURATOR UNIT MT56944 DIMENSION DRAW INIC NJ
2. gt Precision aluminum rod extruded profile acc to DIN17615 hardened warm Precision aluminum rod extruded profile acc to DIN17615 hardened warm anodized natural end face cut nearly burr free Most suitable for base frames and anodized natural end face cut nearly burr free superstructures which are not dynamically loaded LIGHT PROFILE LP 66 44 SPECIFICATIONS SUPPORT PROFILE TP 96 44 SPECIFICATIONS Profile surface mm 809 Profile surface mm 2 1480 Section modulus Wx cm 13 Section modulus Wx cm 29 Wy con 18 Wy 23 Moment of inertia Jx cm 45 Moment of inertia Jx 76 cm 45 Jy 76 Length tolerance according to DIN 7168 medium Length tolerance according to DIN 7168 medium Torsion tolerance mm m 1 Torsion tolerance mm m 1 Straightness tolerance mm m 7 Straightness tolerance mm m 0 7 Weight kg m 2 186 Weight kg m 3 996 Part no for length 3000 mm 49260 3000 Part no for length 3000 mm MT42852N3000 144 SUPPORT PROFILE TP 96 44 Precision aluminum rod extruded profile acc to DIN 7615 hardened warm anodized natural end face cut nearly burr free SUPPORT PROFILE TP 96 44 SPECIFICATIONS Profile surface Section modulus Wx Wy Moment of inertia Jy Length tolerance Torsion tolerance Straightness tolerance mm m Weight Part no for length 3000 mm cm cm cm cm
3. mm O 00 20 EE horizontal and y direction vertical z direction mm 2 202 02 a 017 220012 02 Length mm 32 41 41 356 556 761 Operating pressure bar 3 6 Nominal pressure bar 5 Air consumption PU cm 10 double stroke at 5 bar TracSet base frame for TracLink table board part no MT57431 Maternal TracSet base frame for Trac table board part no MT54819 TracSet base frame for TracLink table board part no MT57431 Pneumatic connection for hose with 4 mm aluminum steel bronze Driving medium Ambience lemperature C Rel Air humidity Air purity level 5 um filtered oiled or unoiled air 10 to 40 5 96 85 96 without condensation normal workshop ambiance 72 MONTRAC 73 POSITIONINGUNIT M1 PU4 S300 Al DIMENSIONS POSITIONINGUNIT M1 PU4 S550M400 Al DIMENSIONS Platform Platform SPU 4 SPU 4 MPU 4 MPU 4 dimension dimensions 200 x 300x 200x 300x mm e mm 550 550 400 400 M1 PU4 S300 Al MT65092 M1 PU4 S550M400 Al MT65094 PM SPU 4 5 1 4 MPU 4 Plattorm dimensions MPU 4 MPU 4 be 200 400 300 400 200 300 mm 200 x 550 300 x 550 E Ja a 1 4 5400 300 MT65093 M1 PU4 M550 Al MT65095 74
4. FIXED CASTER BRLP 75 40 FOR LIGHT PROFILE LP 66 40 580 0 420 MT54270N MONTRAC 165 FOUNDATION ANCHOR BRACKET FW AO 33 49 For floor attachments and connections with constructions incompatible with TracSet made of cast aluminum FOUNDATION ANCHOR BRACKET SPECIFICATIONS Perpendicularity between base surface and mm 01 Dovetail in relation to the flank length 49 mm Weight 0 440 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
5. JI TI 200 300 lt lt mn load capacity 20 kg ms mp transported parts including their mounting on the plattorm lt mp platform weight see table on page 70 4 ms Shuttle weight 2 1 gt see table on page 28 Other Shuttle lengths on request TWIN AXLE SHUTTLE 5 4 DIMENSIONS 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 intormation see operating manual of Shuttle MSH 4 es NENNEN lt mp platform weight see table on page 70 lt lt ms Shuttle weight see table on page 28 Twin Axle Shuttle MSH 4 Part no Part no TC2 M1 SH4 CW L550 2 2WD TC I M1 SH4 CW L550 2 2WD TC2 MT61717 MT65287 M1 SH4 CCW L550 2 2WD TCl M1 SH4 CCW L550 2 2WD TC2 MT58783 MT65286 Other Shuttle lengths on request 32 MONTRAC FREE SPACE FOR SHUTTLE AND SHUTTLE MSH 4 WITH WORKPIECE PLATFORM 200 X 300 MM 200 X 400 MM 200 X 550 MM 210 170 L Trac length 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 310 170 L Trac length Boundary line the area within this boundary line must remain free Dependin
6. W DC A W mVpp 24 40 Aluminum copper steel plastic rubber 10 to 40 5 96 85 96 without condensation normal workshop ambiance 24 19 36 5 4 129 2 24 20 2 4 2 100 8 11510 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 131 115 190 660 lsolationTrac 300 MT56945 IsolationTrac 660 MT56946 including DC DC converter DC DC converter MT506859 MONTRAC PLANT GROUNDING CONCEPT e 24 VDC IPG lo voc LUN SINN VA 1 UD oO IWC QOQ GROUNDING CONNECTION The grounding conductor is led with the supply line trom the switching cabinet to the plant The connection to the system is made by using the grounding element ERE 40 MONTRAC 113 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 electri cally 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 h
7. 11 THE MONTRAC SYSTEM COMPONENTS Montrac stands for absolute flexibility in conveyor technology and thus for practically 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 innova tors More and more often there is a requirement to choose the most ef ficient way If productivity is to be in creased 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 your productivity is to automate and or optimize the material flow This is hardly practicable with classical con veyor systems Montrac can quickly easily flexibly and conveniently help with this project OVERVIEW OF THE MONTRAC COMPONENTS SHUTTLE TRAC TRACLINK The Shuttles are the intelligent The monorail consists of a colorless The TracLink is the connecting ele material handling vehicles and the anodized aluminium rod extruded ment between two Trac sections it centerpiece of every Montrac system profile The conductor rails can run connects the conductor rails and A Shuttle is available with one drive along the left or right of the entire serves as feeding point as well as axis or as twin axle shuttle Each Trac thus allowing a flexible posi support point Shuttle has a sensor which excludes tioning of the control modules The potential col
8. Configuration by montratec PC connection cable T base frame Single leg support MONTRAC 61 EE NN Part no MT56935 MT506157 MT56584 MT56817 62 MONTRAC MONTRAC 63 POSITIONS OF TRACCROSSING CYCLE TIMES TRACCROSSING The TracCrossing has two possible positions Log off Position 1 Position 2 Y The measurements for L assume a log off of the Shuttle for a falling signal from the log off sensor For a log off of the Shuttle for a rising signal of the log off sensor the values for L need to be increased 70 mm each time 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 FREE SPACE FOR SHUTTLES WITH PLATFORM WIDTHS 200 MM 300 MM CYCLE TIMES Twin Axle Shuttle Shuttle L2300 mm Shuttle L2400 mm Shuttle L2550 mm Shuttle L2550 mm LU 80 mm LU 180 mm 350 mm LU 2 350 mm Additional load Additional load Additional load Additional load without max without max without max without max Passage at s s s s s s s s v 30 m min 2 1 2 4 2 9 2 6 2 7 2 7 24 214 12 m min 4 3 4 5 4 8 del 5 7 5 8 mo 59 Depending on the load the free space will need to be increased upward e ow s 64 MONTRAC S
9. M ONTRAC Design Guide Increasing productivity thanks to flexible and intelligent intralogistics 10 2013 issue in English Preliminary Issue 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 respec tive owners and are recognized All data is for informational purposes only is subject to change and is not guar anteed 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 TAMPOCO D Boehringer Ingelheim E Autoliv PRETTL ED ED v Salvatore e VE ESCHENBACH AVIONICS 4 VIMAR Energia positiva REEMTSMA RADINE THE QUALITY CONNECTION LEONI Wire Cable Sala oUrgess ENS V uU Lob um Xj Lm T Boehringer Ingelheim CHIRON VACCINE li Pharmaton 4 MONTRAC MONTRAC 5 MONTRAC IN USE 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
10. distance AB to A Cam 130 mm length A Cam 45 mm MONTRAC 79 MOUNTING SET FOR POSITIONINGUNIT PU 4 PLATFORM WIDTH 200 gt 16 1616 2 1 NN Mounting set for PU 4 platform width 200 mm MT65387 MOUNTING SET FOR POSITIONINGUNIT PU 4 PLATFORM WIDTH 300 MM 467 328 AAA Mounting set for PU 4 platform width 300 mm MT65394 Platform width 300 mm A MT65092 MT65093 L MT65094 MT65095 80 MONTRAC MONTRAC 81 TRACDOOR BASE FRAME FOR POSITIONINGUNIT PU 4 PLATFORM WIDTH 200 MM The TracDoor 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 turning point and can be opened rotated to an end stop and then can em weng beet 200 mm m MT65396 TRACDOOR SPECIFICATIONS TracDoor length tolerance mm 2020 Material Aluminum nickel plated copper plastic Panel Width X Nominal voltage V DC 24 Current carrying capacity between the Trac connections A 40 i on the movable Trac section A 2 9 Ambiance Temperature Ke 10 to 40 Rel Air humidity 5 96 85 without condensation Air purity
11. 550 140 20 12 34 70 lt 4 24 0 16 1 90 4 48 0 80 1 10 MONTRAC SHUTTLE 3 DIMENSIONS 200 300 g 300 400 550 20 L 170 270 420 65 1 D EM 165 157 Part TC2 MT65010 MT65011 MT65012 MT65013 MT65014 20 54798 MT65015 Other Shuttle lengths on request TWIN AXLE SHUTTLE 3 DIMENSIONS 200 300 9 550 20 165 157 Twin Axle Shuttle 3 Part no TC U U rear axle empty MT54801 U GU rear axle empty MT54802 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 intormation see operating manual of Shuttle 3 _ 1 TWIN AXLE SHUTTLE 3 LOAD LIMITS REAR AXLE EMPTY mn load capacity 17 kg ms mp transported parts including their mounting on the plattorm mp platform weight see table on page 70 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 intormation see operating manual of Shuttle 3 L4 III mn load capacity 17 kg ms mp mp platform weight see table on page 70 ms 6 2 kg TWIN AXLE SHUTTLE 3 LOAD LIMITS MONTRAC 27 The center of gravity of the load should be centered and not higher than 130 mm above the
12. MONTRAC 75 WORKING HEIGHT PERMITTED FORCES AND TORQUES ON THE WORKPIECE CARRIER PLATFORM IN THE POSITIONINGUNIT Plattorm top POSITIONINGUNIT Platform length mm Positioning Description Part no 300 single M1 PU4 S300 Al MT65092 400 single M1 PU4 S400M300 Al MT65093 550 single M1 PU4 S550M400 Al MT65094 Nominal pressure Dar EES EE aluminum plattorm locked in PU 4 200x300 200x400 300x400 200x550 300x550 550 multiple M1 PU4 M550 Al MT65095 MY Single positioning Nm ES AC zul zul ACCESSORIES FOR POSMIONINGUNI PU ee 0008 ul Adjust gauge for width 200 mm MT65171 av Single positioning 800 800 800 800 80 Adjust gauge for width 300 mm MT65173 Multiple positioning 80 80 809 Connection cable 5 m with straight socket on one side MT504610 ES EE Connection cable 5 with angled socket one side MT504929 57 Single positioning N 2000 3000 3000 4000 4000 zul Connection cable 10 m with straight socket on one side 507528 DR BEE IN 2000 3000 3000 4000 4000 Connection cable 10 m with angled socket on one side 207222 Single positioning N 1000 1500 1500 2000 2000 FZEzul Proximity switch 0 6 5 PNP with cable 2 m MT508842 Multiple positioning IN 1000 1000 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 f
13. TRACCONTROL 2 UNIT DIMENSIONS kg mm iv DC mA iv DC IV DC mA IV DC mA mA mA PC 2 4 6 8 10 0 7 0 9 1 1 1 3 Es 125 205 20 365 445 24 200 without plug in boards 22 4 BSG 3 Input voltage 500 3500 6000 Aluminum copper steel brass plastic IP 20 10 to 40 5 96 85 96 without condensation normal workshop ambiance MX TC2U TS board FW us SF yo Plug in board for TC2U MX TC2U TS board Part no MT61574 Net weight 9 69 1 x M12 for TracSwitch Connections 2 x M8 for log off sensor TC2U ACCESSORIES Cable M8 4 pin 2 m Blank cover TC2U net weight 40 g Cover tor 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 board MX TC2U IOO board galvanically isolated MX TC2U IO board MT61575 46 8 DIN 8 x DOUT MONTRAC 95 TRACCONTROL 2 ACCESSORIES PLUG IN BOARDS FOR TRACCONTROL 2 UNIT TC2U MX TC2U IOO board MT61576 97 8 x DIN galvanically isolated 8 x DOUT galvanically isolated Part no MT52115 MT61578 MT521149 EX 000003065 000 EX 000003066 000 EX 000003068 000 EX 000003067 000 MT521129 EF 000000783 000 EF 000000782 000 EF 000000447 000 96 MONTRAC TRACCONTROL 2 MFC The Tr
14. 1 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 mastertully fulfilled by Montrac The versatile properties of Montrac allow for 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 stand still 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 mono rail 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 basi
15. A 25 2x25 Wall console MT57910 Input power at nominal load kW 1525 23 TracSet mounting console MT57911 Harmonic filtering Integrated passive filter according to EN EC 61000 3 2 Base framework for lift MT57912 DC at output IV DC 24 28 8 adjustable Control accuracy of output voltage 1 3 96 from set value DC at output A 40 2x40 Output voltage ripple mV lt 200 Current limitation adjustable from 10 110 Al Max 44 max 2 x 44 Ambiance Temperature FE 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 29 9 pushbutton Hat green FASTENING SET FOR POWER SUPPLY DP 40 L 500 460 d Luminous Push button flat red Circuit breaker Emergency Stop TracSupply 40 A MT60506 TracSupply 2 x 40 A MT60508 Use always in connection with IsolationsTrac Square sliding block M6 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 This is necessary due to the conduc tor cross section and because a dangerously high current would flow in case of a short circuit The line must be divided into suitable sections which are then each sup plied by means of a separate power supply unit Th
16. Owing to their special shape the Shuttles are self centered on the monorail Driven by a maintenance free low voltage electric motor that is fed by an inductive non contact energy transmission they reach a speed of 30 m min 900 mm to top edge Each Shuttle has its own control of Shuttle plattorm system which receives its commands from the control cams on the Trac 1340 Possible collisions with other Shuttles or obstacles are detected by an TracCurve 180 R520 base frame MT58642 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 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 L 0025 mm 45229 0025 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 ma
17. Part no MT56935 MT506157 57671 MONTRAC 55 Part no MT58879 56 MONTRAC OVERVIEW OF TRACSWITCH ARENA POSITIONS AND TYPES Pos Pos 2 Pos 3 TracSwitch Arena L Pos 1 4 2 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 FREE SPACE FOR SHUTTLES WITH PLATFORM DIMENSIONS 200 X 300 MM 200 X 400 MM 200 X 550 MM 210 Depending on the load the tree space will need to be increased upward Platform dimensions mm 200 x 300 200 x 400 200 x 550 R350 R350 R380 Depending on the load the free space will need to be increased upward 300 x 400 300 x 550 R400 R410 R440 R875 E 475 ae 58 MONTRAC CYCLE TIMES FOR TRACSWITCH ARENA STRAIGHT ON 1 80 Lil x Qi 559 a n in AB Cam 2 A o Y The measurements L assume a log off of the Shuttle for a falling signal from the log off sensor For a log off of the Shuttle for a rising signal of the log off sensor the values for L need to be increased by 70 mm each time The times mentioned below apply only to the contigurations listed in the drawings and to the acceleration times listed
18. REPRESENTATION WITH SENSORS CONTROL ELEMENTS AND WIRING TRACCONTROL In case of TracControl 1 the TC1 Box Single IRMs are wired on terminal strips in Y Log out sensor the Box Single and Box Double TCT RM According to the function the C Box Double Track switch cable Sensor cable required sensors and actuators are TC1 IRM cable connected to these In addition the interfaces digital inputs outputs and RS232 are available on the terminal blocks TRACCONTROL 2 Log out sensor With TracControl 2 all cables can be easily and quickly connected to the TC2 IRM CAN Track switch cabled respective components via plug in NEC nsorcoble connections Autonomous compo MC AN cable O cable nents 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 Ether net The digital I O interface of the TC2 IRM can be directly picked up on these or on the TC2U 2 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 It is powered by a mainte nance free low voltage motor which is located in the Shuttle axle A Shuttle is available wi
19. Shuttle For more intormation see operating manual of Shuttle 3 NEN NEN NEN END mn load capacity 34 kg ms mp mp platform weight see table on page 70 ms 9 kg 28 MONTRAC SHUTTLE MSH 4 The Shuttles are the intelligent mate rial handling vehicles and the center piece of every Montrac system Owing to their special shape they ride self centered on the monorail It is 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 Trac Control 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 speed 55 m min Robust meachanics Additional load up to 30 kg is possible Additional interface SHUTTLE MSH 4 SPECIFICATIONS Shuttle Length Weight Max total weight kg Sto
20. The TC1 IRM configuration unit serves to contigure the TC1 IRM Intelligent Routing Modules With the aid of soft ware TC1 IRM TC1 ISM Configurator the desired functions can be assigned to an TC1 IRM and the necessary parameters can be configured Further the TC1 ISM Intelligent Shuttle Module in the shuttle can be assigned a new shuttle number TRACCONTROL 1 IRM ACCESSORIES SPECIFICATIONS CONFIGURATOR UNIT Net weight kg Os Material Aluminum copper steel plastic Connection voltage V 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 Trac Control 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 Stan dardized 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 or digital LC boards The TC2U provides for instance an Ethernet hardware inter face to communicate with other controls or host computers For this purpo
21. Triom Antistatic and low power consump tion With Montrac we were able to realize several objectives at one time we saved time optimized control of pro duction processes and efficiency of labor and improved our space utilization Maurizio Romagnoli owner of Tech Pol s r l Efficient and fully automated intralo gistics Based on a positive result gained in a previous project we know we can find a suitable solution to satisfy the require ments in terms of compact dimensions small footprint com se KE patibility with aseptic environments reliability and high avail Lee Men cok es ability Mii Te 5 Thomas Otto CEO of Vetter Pharma Fertigung GmbH amp Co KG Tm i ee ee We are very satistied with the result and service of mon tratec We are currently planning the implementation of two more Montrac lines Ulrich Wilke Production Manager of SEIKO Optical Europe Laboratory 6 MONTRAC product design award 2013 GOOD DESIGN 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 manu facturing and the marketing of 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 contro
22. below The dimensions shown in the drawings are minimum dimensions tor which the manufacturer can guarantee trouble free operation CYCLE TIMES Shuttle L 300 mm Shuttle L 400 mm LU 40 mm 1 160 mm Additional load Additional load without max without max without Passage at 5 5 5 5 5 30 m min 1 8 2 0 2 0 22 2 3 12 m min 9 7 4 AS 4 8 5 0 Shuttle L 550 mm LU 330 mm Additional load max 5 2 6 5 6 Twin Axle Shuttle Shuttle L 550 mm LU 330 mm Additional load without 5 2 4 5 3 max 5 Zu 5 6 MONTRAC 59 CYCLE TIMES FOR TRACSWITCH ARENA CURVE Log off TracLink 80 AR Cam 1 The measurements for L assume a log off of the Shuttle for a falling signal from the log off sensor For a log off of the Shuttle for a rising signal of the log off sensor the values for L need to be increased 70 mm each time 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 Passage at v 30 m min v 12 m min Twin Axle Shuttle Shuttle L 550 mm LU 375 mm Additional load Shuttle L2400 mm LU 2 225 mm Additional load Shuttle L2300 mm LU 2 125 mm Additional load Shuttle L 550 mm 1 375 mm Additional load without max without ma
23. class F without condensation with relative moisture 85 normal workshop ambiance LIFT CHAOS TECHNOLOGY LCT SWITCHING CABINET SPECIFICATIONS 3 x 400 480 V 50 Hz 60 Hz 800 IP 21 vertical 2 600 380 350 104 MONTRAC MONTRAC 105 SWITCHING CABINET LCT DIMENSIONS L CONNECTION TRAC DIMENSIONS R Connection Trac dimensional drawing mirror inverted 600 397 Switching cabinet LCT Part no Variant 1 2 3 Level MT58558 R Connection Trac complete MT57463 Variant 2 4 7 Level MT58560 L Connection Trac complete MT57457 MOUNTING SET FOR SWITCHING CABINET LCT LIFT BASE FRAMEWORK excluding safety enclosure d han 414 2080 414 _ 1 SLL 55 40 SP 64D 40 DEK 40 DP 40 L 600 545 397 Example dimensional drawing for Litt itchi i platform 900 mm Square sliding block M8 for LCT switching cabinet MT59620 stroke 1000 mm 106 MONTRAC LIFT FIXTURE ON A TRACSET STRUCTURAL FRAMING max 500 min 230 700 260 180 260 LIFT WALL MOUNTING max 500 min 230 700 260 180 260 p B 2250 Rea Ui a max 200 m
24. edge of Shuttle platform 346 __ IO Type H base frame MT58230 Part no Type L base frame MT56818 122 DOUBLE TRACSWITCH SUPPORT FRAMEWORK 2 5 504 900 mm to top edge ot Shuttle platform 700 568 PA AT Q LO N N AT s f zm o Double TracSwitch base frame MT56826 900 mm to top edge of Shuttle platform E Tos Double TracSwitch base frame MT5767 1 TRACCURVE 90 R520 BASE FRAME MONTRAC 123 4 525 80 5 N TRACCURVE 45 R520 BASE FRAME 525 257 900 mm to top edge of Shuttle platform TracCurve 90 8520 base frame MT58580 327 D N 739 dl 4 900 mm to top edge of Shuttle platform EI TracCurve 45 R520 base frame MT58589 124 125 SPECIAL 5 TRACCURVE 180 R520 BASE FRAME Customer specitic special compo nents are listed further down The development engineers of the mon tratec AG are pleased to offer sup port and guidance in the implemen tation of special solutions The contact details are shown on the back of this catalog 727 735 HH SHUTTLE MSHI 4 INDUCTIVE
25. group com INDEX OF CONTENTS MONTRAC 7 ABOUT MONTRAC CHAOS TECHNOLOGY MONTRAC CONFIGURATOR IACCONIROL SHUTTLE MSH 4 WORKPIECE PLATFORM TRAC TRACLINK TRACCURVE TRACSWITCH TRACSWITCH ARENA TRACCROSSING ERGOTRAC POSITIONINGUNIT PU 4 TRACDOOR TRACCONTROL LIFT TRAC ley ISOLATIONTRAC GROUNDING CONCEPT TRACSET BASE FRAMES SPECIAL COMPONENTS ik CoE Subject to moditications 16 18 24 28 2 Se 218 4 48 54 60 64 67 81 84 100 109 TS MS 125 5 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 flexibil ity 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 tully modular and consists of system components In contined spaces or across several floors Montrac reliably and economically performs transport tasks in the assembly automation supports production tasks and processes from batch size
26. 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 status indication visualization etc MONTRAC TCT IRM CONFIGURATION The Montrac TCT IRM ISM Configurator software assigns the required TC1 IRM types and the corresponding parameters There are 14 module types available from a drop down menu as a standard version The range of functions includes every thing 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 TC1 IRM 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 TC1 IRM is needed at each stopping point in the system to detect a present Shuttle and to start the Shuttles The TCT IRM Basic assembly serves this purpose It consists of a TC1 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 1 with or without 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 k
27. interconnected profiles is 3000 N a An Allen key is sufficient for assembly ROBUST AND FLEXIBLE MONTRAC 133 Precise heavy duty vibration proof connections between two elements with dovetail geometry by means of clamp ing 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 134 TracSet is o universal modular system for structural framing The system allows quick assembly without mechanical processing of the profile ends With a minimum of individual elements 10 basic components a great variety of assembling possibili ties is possible TracSet can be adjusted easily quickly and flexibly no drilling no pinning 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 easy fast and flexible precise and dimensionally stable TracSet connections are vibration proof and therefore highly suitable for demanding applications The connections are precise regard less of the profile end processing TracSet allows to set up linear con nections as well as connections with adjustable angles Its high flexibility permits the st
28. level normal workshop ambiance 82 MONTRAC MONTRAC 83 TYPE OVERVIEW OF TRACDOOR SINGLE DOUBLE BASE FRAME 1 FOR TRACDOOR The opening direction and the pivot The opening direction is treely selectable point position can be freely selected 3000 2000 504 80 5 Clear width 1850 900 mm to top edge of Shuttle platform 983 981 767 AAA Base frame for TracDoor 2000 3000 a wl TracDoor single L 2000 mm TracDoor single L 3000 mm MT56954 900 mm to top edge of Shuttle platform ACCESSORIES FOR TRACDOOR Part no Proximity switch M8 PNP pluggable MT508845 Connection cable 5 m with straight socket on one side 504610 Connection cable 10 with straight socket on one side MT507528 SN Base 1 tor TracDoor MT92064 Base frame 2 for TracDoor 2000 MT92066 MT92066 Base frame 2 for TracDoor 84 MONTRAC TRACCONTROL 1 COMPONENTS TRACCONTROL 1 IRM The TC1 IRM Intelligent Routing Module is an optoelectronic com munication module for data exchange allowing Shuttle Trac and master control to interact with each other The Shut
29. misalignment IN 1500 Fastening torque of screw s Nm Weight kg 0 060 Part no MT65474 MONTRAC 153 in clamped state For connection of two dovetails intersecting at right angles 45 angle connector CORNER CONNECTOR EV 3 45 40 3000 6 0 1 MT65473 154 MONTRAC CORNER CONNECTOR EV 2 40 in clamped state 90 angle connector for low load in clamped state CORNER CONNECTOR SPECIFICATIONS CORNER CONNECTOR EV 2 40 Resistance to misalignment N 1500 Fastening torque of screws Nm Perpendicularity of clamping grooves mm TE ici e 19 mm Weight kg 0 050 MT65468 Part no load 90 angle connector for medium CORNER CONNECTOR EV 3 40 PACK OF 4 3000 6 0 03 related to a length of 45 mm MT65469 pack of 4 pre assembled and packed CORNER CONNECTOR EV 4 40 PACK OF 4 CORNER CONNECTOR EVD 4 40 Aug H e CORNER CONNECTOR SPECIFICATIONS Resistance to misalignment Fastening torque of screws Perpendicularity of clamping grooves related to a length of 70 mm Weight Part no N mm kg in clamped state MONTRAC 155 90 angle connector for high load 90 angle connector for medium load with cable duct CORNER CONNECTOR EV 4 40 PACK OF 4 4500 6 0 04 related to a length of 70 mm 0 250 MT65471 pack of 4 pre assembled and packe
30. 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 the Shuttle and TracControl 1 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 quota tion management of the montratec AG PRINCIPLE Technical information Hall drawing Ancilllary conditions dimensions LAYOUT Track components Base trames and Shuttle Drive control components QUOTATION Transmission of the PX file to montratec Quotation for transport system LINKING OF INFORMATION 235 ee see ace nee om 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 also 3D contours and surface elements can be added 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 accu rate 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 r
31. platform TracLink table board MT57431 TracLink single leg support MT56817 118 MONTRAC TRAC TRAC DOUBLE LEG SUPPORT BASE FRAME N 652 80 5 TRACLINK TRACLINK DOUBLE LEG SUPPORT BASE FRAME 560 900 mm to top edge of Shuttle platform E 1 0 Trac Trac double leg support MT91569 900 mm to top edge of Shuttle platform Tos TracLink TracLink double leg support MT58298 Ee N TRACLINK TRAC DOUBLE LEG SUPPORT BASE FRAME 560 2 5 TRACLINK 34 SUPPORT BASE FRAME for long lines 504 80 5 2 4 MONTRAC 119 900 mm to top edge of Shuttle platform TracLink Trac double leg support MT58299 900 mm to top edge of Shuttle platform E T Ma 1 TracLink 3 leg support MT57948 120 MONTRAC MONTRAC 121 4 LEG SUPPORT BASE FRAME TYPE T SUPPORT FRAMEWORK e g for 2 x TracCurve 90 TracSwitch TracCrossing E N 2 5 652 504 727 80 5 900 mm to top edge of Shuttle platform 900 mm to top edge of Shuttle platform Part no MT58301 SE Type T base frame MT56584 TYPE H BASE FRAME 504 Lt 900 mm to top edge of Shuttle platform 900 mm to top
32. side Connection cable 10 m with angled socket on one side TC1 IRM contiguration by montratec TC1 IRM Contigurator Unit Box Single Box Double 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 go to www schmid group com Part no MT520292 MT508845 MT45428 47200 MT90730 21 44 MT45314 MT45315 MT90759 MT57020 MT58183 MT58184 MT57008 MT57442 MT57023 MT57024 MT92008 MT56925 Part no MT56986 MT57184 MT57579 MT504610 MT504929 MT507528 MT507529 MT56944 MT58693 MT56984 MT56985 MONTRAC 87 ACCESSORIES FOR TRACCONTROL ELECTRIC SWITCH 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 off MT57023 power off for shuttle visible 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 CAMS SPECIFICATIONS Net weight kg Connection voltage V DC Current consumption A Ambiance lemperature Rel Air humidity Air purity level Electrically switchable cam on pow MT57023 er off for shuttle invisible 03 24 0 5 10 to 40 5 96 85
33. the so called Chaos Technology which makes it possible to operate a 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 ac cording to rules which support the process and provide optimum supply of goods to the stations So the Shuttle and the product controls the rail system self 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 TRACCONTROL 2 TracSwitch Litt PositioningUnit SupoTrac ShuttleLock WebGUI contig status I O Interface Ethernet Modbus TCP I O interface 3 a TC2 IRM Shuttle TC2 IRM TC2 IRM montrac Shuttle CAN bus Y HIGHER LEVEL CONTROL SYSTEM Ethernet MDAC HTTP syslog NTP SSH Compared to the TracControl 1 TracControl 2 interconnects the decision points modules along the rail system by means of a CAN bus and to man age the decision points via one or more central controls The configuration of the drive control is performed centr
34. 2 040555 0 020 MT65470 MT65464 CLAMPING ELEMENT LONGITUDINAL LONGITUDINAL SLL 12 40 CLAMPING ELEMENTS SPECIFICATIONS Resistance to misalignment of two joining profiles Torque value of screw s Parallelism of clamped surfaces Weight Part no N mm kg in clamped state MONTRAC 151 For connection of dovetail profiles under low load For the connection of dovetail pro files under high load and increased clearance CLAMPING ELEMENT CLAMPING ELEMENT LONGITUD LONGITUD LONGITUD LONGITUD SLL 12 40 SLL 55 22 40 750 3000 6 0 02 21102 0 016 0096 MT65465 MT65466 152 MONTRAC CLAMPING ELEMENT LONGITUD LONGITUD SLL 20 22 40 CLAMPING ELEMENT SPECIFICATIONS Resistance to misalignment N Torsional strength Nm Torque value of screw s Nm Parallelism mm Weight kg Part no in clamped state CLAMPING ELEMENT LONGITUD LONGITUD SLL 20 22 40 of two joining profiles 1350 6 of clamped surtaces a 0 0 0 022 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 0 070 65475 CROSS CONNECTOR 40 CORNER CONNECTION EV 3 45 40 in clamped state CORNER CONNECTORS AND CROSS CONNECTORS SPECIFICATIONS CROSS CONNECTOR KV 40 Resistance to
35. 220 Part no Accessory tor TracCurve 90 R520 Type L base frame MT56818 O 560 Base frame 90 MT58580 Type T base frame MT56584 Base frame 180 MT58642 TRACCURVE 45 R520 DIMENSIONS TracCurve R220 X TracCurve R520 45 R220 inside conductor rail MT56097 1 45 R520 inside conductor rail MT58202 45 R220 outside conductor rail MT56098 Ki 45 R520 outside conductor rail MT58208 Accessory tor TracCurve 45 R220 Accessory for TracCurve 45 R520 a 5 817 use 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 A 90 TRACCURVE R220 Platform dimensions 200 x 400 200 x 550 300 x 550 R350 R380 8410 Bo R200 R300 R330 49 Platform dimensions 200 x 400 200 x 550 300 x 550 R350 R380 R410 57 46 MONTRAC MONTRAC 47 FREE SPACE WITH SHUTTLE TRACCURVE 90 R520 ASSEMBLY EXAMPLE The support between the rails and the base frame is usually at the TracLink Platform dimensions 300 400 550 400 550 ef R450 R400 SLL SLL 0 210 310 SP 64 D 622 210 am a EN more intormation about the componen
36. 96 without condensation normal workshop ambiance 88 MONTRAC MONTRAC 89 FLAG A CAM FOR PU 4 U MT57008 FLAG AB CAM MT58183 ACCESSORIES FOR TRACCONTROL SHUTTLELOCK MT56925 DIM DRAWING 93 The ShuttleLock serves to localize a Shuttle at hand work place or on the lift SHUTTLELOCK SPECIFICATIONS Net weight kg 0 560 Connection voltage IV DC 24 Current consumption A 025 co j Ambiance Temperature 10 40 Rel Air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance ACCESSORIES FOR SHUTTLELOCK 15 Part no Proximity switch M4 PNP with cable and connector 58 for ShuttleLock MT520292 90 MONTRAC MONTRAC 91 ACCESSORIES FOR TRACCONTROL 1 IRM BOX SINGLE DIMENSION DRAWINC ACCESSORIES FOR TRACCONTROL 1 IRM BOX DOUBLE DIMENSION DRAWING The Box double is used for wiring a Montrac system The Box double is the interface between one or two TC1 IRMs and The Box single is used for wiring a Montrac system The Box single 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 so is their peripherals or master control Since all the inputs and outputs of the TC1 IRM can be picked up in the box so is therefore universal therefore universal
37. APACITY During installation the potential mmm number of fully loaded Shuttles on a Shutiles abl 9 track section needs to be considered section supported at both ends monorail must be supported over TP 66 LI 2960 mm 56926 2960 certain track sections uua nd A gt xxxx any length between 60 and MT56926 xxxx The permissible length of a track 2960 mm is available available section supported at both ends E Lzul depending on the number of Shuttles must comply with the follow T Ch Guide profile conductor and cover profile ing table The monorail 1 can also are included in the scope of delivery be equipped with a reinforcement 2 TP 66 In this case the permissible Lzul permissible length length of a supported track section Deeg SE P3 may be larger see table below View A View B Lzul permissible length 2 27m 727 2 4 m 3 7 m ASSEMBLY EXAMPLE The support between the rails and the base frame is usually at the TracLink ACCESSORIES FOR TRAC Part no SLL SLL Guidance profile MT904 1 6 xxxx DEK DEK Conductor rails MT508346 xxxx SLL SLL Cover protile MT91257 xxxx DEK DEK T slot cover L 3000 mm 56973 SLL SLL Trac base frame MT54819 SP 64 D Single leg support MT91565 Trac Trac double leg support MT91569 TracLink Trac 3 leg support MT57948 4 leg support MT58301 For more info
38. AY AND OPERATING FUNCTIONS OF THE TC2 MFCs ear ES a CR B OTTO 18 11 iii DUTOT The positions and travel destinations The statuses of the Montrac compo Error messages are displayed and of the individual shuttles are dis nents such as TracSwitch lifts etc are can be reset played displayed and can be changed Advantage enables remote diagnos Advantages visualization and clearly Advantage system status is intuitively tics and support laid out display of the material flow apparent of the whole system a Various system specific data are displayed and logged BERND i i aac Advantages a Material tracking a Error reproduction GUU a Shuttle material and status report it 11 1111 TC2 MFC ACCESSORIES Part no PC 19 Industrial PC acc to Spec Win RAID EA 000001 666 000 USV Back ups CS650 USB BK 650El EG 0000001 12 000 Angle bracket V2A computer fixture CPU SWIT RE 16 012 0169 0001 17 touch screen monitor serial USB EA 00000101 4 000 PC extender Lindy junior set EA 000000808 000 3 in 1 KVM cable PS 2 VGA St St 2m EA 000000840 000 SUB D extension Bu St 9 pin 1 8 m EX 000001101 000 Holder AIMg3 0100X0150X2 16 012 0232 0000 98 MONTRAC TRACCONTROL 2 CONTROL COMPONENTS TRACCON
39. CKET EW 40 ROUND EWR 40 Weight ka 0 204 0 172 45851 45852 mo MONTRAC 159 ROTARY DISK DS 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 DS 0 40 REINFORCED KEV 40 Weight kg 0 024 0 077 Part no MT408557N MT46199N 160 MONTRAC MONTRAC 161 SPACER ELEMENT LONG DEL 40 BRACKET FOR PROTECTIVE SCREEN HSS 40 Hole diameter 6 5 mm protective screen For connection of dovetail profiles in clamped state under medium load For the connection of outer Fastening screws M5 dovetails under medium load Hinge of aluminum anodized natural for swing doors SPACER ELEMENT SPECIFICATIONS BRACKET FOR PROTECTIVE SCREEN AND HINGE SPECIFICATIONS SPACER ELEMENT SPACER ELEMENT BRACKET FOR PROTECTIVE HINGE 5 40 LONG DEL 40 SHORT DEK 40 SCREEN HSS 40 Weight kg 0 110 0 080 Weight kg 0 034 0 300 Pan no MT57446N MT57447N Part no MT48310N MT45160N 162 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 p
40. N cable M12 1 m 107 CAN cable M12 2 1 x GND CAN cable M12 5 m 1 8 pin JST connector CAN cable M12 10 m 2 CAIN Detect Start cable TC2 IRM 2x 24V SC 2x GND C2 IRM supply cable Dimensions L x W x H mm 102x36x11 Cable to TC2 IRM sensor Ambiance Temperature Ke 10 to 40 See Ni Rel Air humidity 5 96 85 96 without condensation Cable to TC2 IRM consumer Air purity level normal workshop ambiance Y Vert 5 pin M12 ST to 2 x MI2 socket MONTRAC Part no MT61613 MT61614 MT61615 Part no MT521121 MT521122 MT521123 MT521124 MT521117 M1521118 11921119 MT521120 MT521125 MT521126 MT521127 MT521128 MT61470 MT61446 MT61444 MT65262 MT61612 EX 000010484 000 100 MONTRAC MONTRAC 101 CYCLE TIMES OF SHUTTLE IN LIFT The litt allows the vertical transport of the Shuttles Use the following tasks Forwards in Forwards in forwards out backwards out as examples Connecting two or more systems of Cycle times s platform length 5 5 different work heights Chula 200 45 48 Taking shuttles from a station to a i Shuttle 400 mm 4 8 Ore ceiling system or vice versa Protection of employees in the lift Shuttle 220 mm 9 0 6 3 area is imperative Twin Axle Shuttle rear axle empty 550 mm Su 6 3 Twin Axle Shuttle 550 mm I3 6 5 Travel time of lift with up 1017 kg load stroke lt 0 45m 2 Travel time s Travel time of lift with up tol7 kg load stroke gt 0 45m st
41. Shuttle load Empty Full Empty Full Tilting time 5 1 1 Throttle position on piston rod side Open by 1 revolution Open by 1 revolution Throttle position on drive cylinder on piston bottom side Open 1 revolution Open 1 revolution 70 MONTRAC MONTRAC 71 POSITIONINGUNIT PU 4 SUPPORT ON A TRACSET PROFILE BASE FRAME 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 Support by means of single leg supports part no MT5681 7 and support for ErgoTrac part no MT58594 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 WI n WII ifa Support for ErgoTrac oingle leg support Single leg support wu Ir no MT58594 11 mT56817 part MT56817 51 SUPPORT ON THE TOP OF A FLAT TABLE BY TRACSET Support on table board by means of a TracSet frame base for Trac table board part no MT54819 and TracSet base frame for TracLink table board part no MT57431 POSITIONINGUNIT PU 4 SPECIFICATIONS pneumatic 300 300 400 400 550 S0 mm mm mm mm mm mm PositioningUnit for platform length single multiple single multiple single multiple Net weight kg 8 9 7 11 11 14 Positioning accuracy
42. T504929 MT507528 MT507529 MT520292 66 MONTRAC MONTRAC 67 ERGOTRAC MINIMUM DISTANCE UNTIL CHANGE OF DIRECTION With the ErgoTrac a manual work station can be set up more ergo nomically The workpiece plattorm is tilted 25 towards the operator This makes the platform ergonomically more easily accessible and improves 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 E manual work is performed A simple support Supolrac absorbs the forces that result from an operation taking place on the Shuttle The ErgoTrac can only be used for the Shuttle L2300mm and L 400mm Run in Move out ERGOTRAC SPECIFICATIONS GAPS Net weight kg 12 Shuttle Shuttle L 300 mm Shuttle L 400 mm Shuttle L 550 mm Twin Axle Shuttle Tilting time See table Tilting Times Run in L min 95 mm 195 mm 345 mm 325 mm Tilt angle 25 Move out L min 95 mm 195 mm 345 mm 345 mm Operating pressure bar 3 6 Nominal pressure bar D Air consumption at 5 bar cm cycle 144 6 Pneumatic connection Hose 4 6 mm 2 7 4 mm Driving medium 5 um filtered oiled or unoiled air End position monitoring Magnetically actuated cylinder switches Life time gt 10 switching operations Aluminum nickel plated copper plastic brass Steel bronze Nominal voltage IV DC 24 Current carrying capacity between the Trac connections A 40 on th
43. TROL 2 IRM TC2 IRM The TracControl 2 IRM TC2 IRM TracControl 2 IRM is an opto electronic communication MX TC2 IRM BASIC with cable detect start A und AB Cam MX TC2 IRM CAN with cable CAN Y distributor A and AB Cam MX TC2 IRM CURVE with cable to sensor and AB Cam module for data exchange between the shuttle and the controller allow ing 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 commu nication 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 1 components as a different infrared transmission proto col is used for the TracControl 2 TRACCONTROL 2 WIRING Track switch cable M12 8 pin 1 5 m Track switch cable M12 8 pin 3 m Track switch cable M12 8 pin 5 m TRACCONTROL 2 IRM SPECIFICATIONS Net ight GE El Track switch cable M12 8 pin 10 m P V DC 2 i Sensor cable M8 3 pin 1 5 m E ti t24VD A urrent consumption a V DC mA 40 Max load t with 24 V DC A circui ax load current wi A 1 outputs shor circuit proof Connections 2 identically configured 8 pin JST connectors Sensor cable M8 3 pin 10 m 3 x DIN 3x DOT CA
44. UPOTRAC The SupoTrac serves as a product support at machining stations to prevent the Shuttle trom being intluenced by outside forces The ShuttleLock included in the scope of delivery prevents the Shuttle from being moved manually out of the IRMs operating area during process ing The SupoTrac is not suitable for stations with press operations The SupoTrac further makes claims concerning ergonomics or safety regulations for manual workstations SUPOTRAC SPECIFICATIONS Net weight Connection voltage ShuttleLock Current consumption ShuttleLock Material Ambiance Temperature Rel Air humidity Air purity level kg IV DC A PC 4 2 24 0 5 aluminum copper plastic brass steel rubber 10 to 40 5 96 85 without condensation normal workshop ambiance SUPOTRAC DIMENSIONS 62 MONTRAC 65 300 400 550 62 314 414 564 SupoTrac with ShuttleLock 42415241614 for platform widths 200 and 300 MT56933 ACCESSORIES FOR SUPOTRAC Single leg support Trac TracLink 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 PNP with cable and connector 58 for ShuttleLock Part no MT5681 7 MT57431 MT504610 M
45. acControl 2 Material Flow Controller TC2 MFC is used to visualize control and record the 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 Shure 19 In connection with the intelligent 1111111111111111111111111 TID TracControl 2 controller all transport movements can be controlled and 5 2 blockades traffic jams avoided 5 achieve optimum utilization The dE user friendly MFC GUI graphical user d 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 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 Interface to the GUI of the TC2 MFC Interface for connection to the Host Manufacturing Execution System MES PONO with the SECS GEM protocol Interface for communication with external control elements such as robots handling systems etc through the OPC protocol MDAC Interface for communication with TC2U based on UDP MONTRAC 97 DISPL
46. acing order Magnetic tape 10 10 80 L 80 1855 2000 120 850 min 595 Track section L Hub X 560 1935 157 y Au A T 217 A gt 85 ER 375 120 hd E El 65 Foot F AO a 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 Nominal voltage Nominal power Type of protection Installation type Weight Dimensions x W x A kg MV DC A DC A DC kg IV DC A DC DC kg AC w kg mm MONTRAC 103 3 x 380 480 V 50 Hz 60 Hz 219 24 V DC 096 15 5 IP 20 Vertical control cabinet 270 775 42 25 20 Vertical control cabinet 22 500 42 25 IP 10 Vertical control cabinet KIo 10 to 40 Humidity
47. al round Cross connector Corner connection Corner connection Abbreviation AK 96 40 SLL 55 40 SLL 20 40 SLL 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 MT48618 MT65470 MT65464 MT65465 MT65466 MT65467 MT65475 65474 MT65473 MT65468 137 Page 149 150 150 151 151 152 152 153 152 154 138 OVERVIEW TRACSET COMPONENTS Description Corner connection Corner connection Corner connection Clamping profile Front Side Adapter Base angle 90 angle bracket Adjusting bracket Adjusting bracket round al Rotary disk ET Pi d FK A 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 DS 0 40 Part no MT65469 MT65471 65472 MT41133N MT57637N MT45715N MT45716N MT45851N MT45852N MT408557N OVERVIEW TRACSET COMPONENTS Page Figure Description 154 Cross element reinforced 155 Spacer element long 155 Spacer element short 156 Bracket for protective screen 156 Hinge 157 Articulated foot for support profile 157 Articulated foot for support profile 158 21 Articulated foot for light profile 158 Swive
48. ally on the TracControl 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 MDAC Montrac specific communication protocol based on UDP 21 22 MONTRAC TRACCONTROL 2 TracSwitch WebGUI contig status S I O Interface Ethernet Modbus TCP MFC OPC SECS GEM PositioningUnit SupoTrac ShuttleLock TC2 IRM CAN bus Ethernet MDAC HTTP syslog NTP SSH SECS GEM OPC I O interface TC2 IRM Shuttle TC2 IRM montra Shuttle TC2 IRM HIGHER LEVEL CONTROL SYSTEM Building on TracControl 2 a Material Flow Controller MFC is further inte grated 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 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 specific communication protocol based on UDP APPLICATION EXAMPLE FOR A MONTRAC SYSTEM MECHANICAL LAYOUT IN 3D VIEW CREATED WITH CONFIGURATOR SOFTWARE MONTRAC SCHEMATIC
49. ansport track to complex networked transport and manufacturing systems for automated manufacturing the TracControl of Montrac offers the tailor made and flexible control solution TRACCONTROL CONTROL SYS TEM TracControl 2 TracControl 2 TracControl 1 Interfaces protocols Performance TRACCONTROL 1 TracControl lis 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 reduced to a minimum a flexible extension is possible at any time As an option communication is possible with external control elements e g PLC via I O 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 single 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 Ether net 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 TracContro
50. as a positive impact for the appearance of the whole plant LUNES GROUNDING CONTACT ELEMENT By mounting the grounding contact elements a conducting connection via the TracSet clamping elements is generated Thus the monorail is mounted electrically conducting onto the different support frameworks 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 CORNER CONNECTION By screwing in the two grub screws into the corner connections the isolating anodized coating is destroyed at the connection points This ensures a conducting connection between the individual aluminium profiles of the TracSet base frames 1141 GROUNDING CONTACT ELEMENT The clamping elements in the installed grounding contacts destroy the anodized coating in detined places and thus create a permanent contact between the monorail track system and the TracSet base frame The conversion kit for electrically conductive SLL clamping elements consists of cutting bush and spring Example of use GROUNDING ELEMENT ERE 40 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 i
51. d CORNER CONNECTOR EVD 4 40 3000 6 0 04 related to a length of 45 mm 0 200 MT65472 156 MONTRAC 157 CLAMPING PROFILE SP 64D 40 BASE ANGLE BW 40 Adapter with double row hole pat 0 05 E A tern For firm base connections on the CLAMPING PROFILE AND PROTECTIVE SCREEN SPECIFICATIONS floor or on table boards Weight kg 0 040 Part no MT41133N E For the connection of two 2 nents arranged at right angles to each other and which can be indi vidually adjusted 440 05 FRONT SIDE ADAPTER 5 40 Og Dovetail profile for front side fastening at a LP 66 40 or TP 66 40 profile FRONT END ADAPTER SPECIFICATIONS Mx perm Nm 50 My perm Nm 50 Ni CO BASE ANGLE AND ANGLE BRACKET SPECIFICATIONS Fz 900 o BASE ANCLE BW 40 A Fastening torque of screw Nm Weight kg 0 230 Weight kg 0 360 0 220 Part no MT57637N Part no 10 50715 5716 158 MONTRAC ADJUSTING BRACKET EW 40 For the connection of two compo nents arranged at right angles to each other and which can be indi vidually fixed in two axis 9 Adjusting bracket for angular joints ADJUSTING BRACKET SPECIFICATIONS ADJUSTING BRACKET ADJUSTING BRA
52. e movable Trac section A DES Ambiance Temperature C 10 to 40 Rel Air humidity 596 85 without condensation Air purity level normal workshop ambiance Max load without Shuttle incl platform kg Shuttle with length L 300 mm 132 Shuttle with length L 400 mm 209 68 MONTRAC ERGOTRAC DIMENSIONS ErgoTrac with ShuttleLock for platform width 200 mm MT56952 and 300 mm ACCESSORIES FOR ERGOTRAC Single leg support Support for ErgoTrac TracLink table board base frame Trac table board base frame Cylinder switch PNP pluggable for cylinder 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 PNP with cable and connector S8 for ShuttleLock Part no MT56817 MT58594 MT57431 MT54819 MT506885 MT504610 MT504929 MT507528 MT507529 DIES AC MONTRAC 69 HOLDING MOMENTS OF THE TILTING MOVEMENT AT 5 BAR MHX Shuttle platform Shuttle The holding moments may be utilized only when the shuttle platform is appropriately supported HOLDING MOMENTS Holding moments In horizontal position In inclined position MHx 13 Nm 13 Nm Mhx 13 Nm 10 Nm TILTING TIMES Direction of movement From horizontal to inclined position From inclined to hori zontal position
53. ed by 360 Depending on the application different TracSwitch positions are necessary TRACSWITCH COLLECT TYPES TracSwitch Collect L TracSwitch Collect T TracSwitch Collect R Pos 4 is equal to Pos l turned by 360 Depending on the application different TracSwitch positions are necessary Depending on the load the free space will need to be increased upward 300 x 400 300 x 550 1 TracSwitch Collect T RIO R300 200 223 239 480 An additional flag part no MT57456 must be Sichtlinie mounted on the TracSwitch Collect T since the Distanzsensor Shuttles move toward each other and may blind each other with the distance sensor this could lead to faults 22 MONTRAC MONTRAC 53 CYCLE TIMES TRACSWITCH STRAIGHT ON CYCLE TIMES TRACSWITCH CURVE TracLink TracLink TracLink IRM A Cam TracLink IRM A Cam The measurements for L assume a log off of the Shuttle for a falling signal from the log off sensor 1 The measurements for L assume a log off of the Shuttle for a falling signal from the log off sensor For a log off of the Shuttle for a rising signal of the log off sensor the values for L need to be increased For a log off of the Shuttle for a rising signal of the log off sensor the values for L need to be increased by 70 mm each time by 70 mm each time The times mentioned below apply only to the configurations listed in the drawings and to the acceleration times listed The t
54. ength A Cam 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 A ___ 80mm 120mm CYCLE TIME FOR INCREMENT b IN MULTIPLE POSITIONINGUNIT MPU 4 Cycle time l Cycle time Shuttle 3 ICT Shuttle MSH 4 Increment b Me Twin Axle Shuttle with eer Twin Axle Shuttle with with maximum load with maximum load is maximum load is maximum load s s 40 mm 0 82 0 82 0 66 0 66 50 mm 0 86 087 0 76 0276 60 mm 0 90 0 94 0 85 0 85 80 2 1 09 1 00 1 00 100 mm 1 44 1 49 1235 kog 150 mm 1 48 2 140 1 40 200 mm 1 62 1 55 145 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 Cycle time Cycle time du Sank 5 NN Shuttle MSH 4 Increment d Twin Axle Shuttle with Twin Axle Shuttle with with maximum load with maximum load is load is 1252 load 5 S 250 mm 2 40 2 60 2 40 2 40 300 mm 222 2 80 2 60 2 60 350 2 80 2 90 2 70 2 70 400 mm 3 00 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 tront 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
55. equired 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 compo nents This considerably simplifies and accelerates the creation of a layout and also ensures that only the actually required components appear in the parts list So without any programming skills the control and or control elements required can be configured LIBRARY ees dai lt LO AAA Various basic configurations of bypasses are stored in the integrated library These frequently used assem blies 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 MONTRAC 17 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 a 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 tr
56. es 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 CONFIGURATOR THE CONFIGURATION SOFTWARE WITH UNLIMITED POSSIBILITIES hie Ane The Montrac Configurator is a very easy to use and free software that can Dee oe CLAS A E seran scene Mc emn DS create individual transport system layouts with a few mouse clicks In the D fi t Il standard t a contigurator all standard components BU 5 of the Montrac system are stored in a k 3 product library These also 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 independently detects the connection points 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 LAYOUT CREATION The configuration of a Montrac layout is very simple Whether based on known dimensions
57. ese sections are electrically decoupled from one another by IsolationTracs ISOLATIONTRAC SPECIFICATIONS Nominal voltage Current carrying capacity Material Ambiance lemperature Rel Air humidity Air purity level DC DC CONVERTER SPECIFICATIONS Input voltage Operating range Nominal input current Input power DC output voltage Control accuracy of output voltage DC output current Output power Output voltage ripple Material Humidity class according to DIN 40040 Cooling Ambiance lemperature Rel Air humidity Air purity level 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 These DC DC converters are con nected on the input side to the power rails of an installation section and on the output side to the IsolationTrac MONTRAC 111 starting a twin axle shuttle There are two IsolationTrac versions the IsolationTrac 300 mm and the IsolationTrac 660 mm IsolationTrac 300 mm is used in systems in which Shuttles are driven by a driven axle incl Shuttle with empty rear axle IsolationTrac 660 mm is used in systems in which Shuttles are oper ated by two driven axles Twin Axle The DC DC converter limits the Shuttle current on the IsolationTrac to max 4 2A This current is sufficient for M DC Al V DC DC A
58. g on the load the free space will need to be increased upward 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 300 mm and 300 mm x 550 mm Other dizes and the num ber 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 web site www montratec com at Support Forms If requested by the customer the prisms can also be placed by montratec AC PLATFORM SPECIFICATIONS Net weight 200 x 300 mm 200 x 400 mm 300 x 400 mm 200 x 550 mm 300 x 550 mm Ambience lemperature Rel Air humidity Air purity level Minimum requirements compatibility kg kg kg kg kg PC MONTRAC 33 2 3 O23 30 4 6 SE 10 to 40 5 96 85 96 without condensation normal workshop ambiance Shuttle 3 and Shuttle MSH 4 34 MONTRAC MONTRAC 35 TRAC PLATE DIMENSIONS 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 t
59. he Centering sleeve control modules The Trac is compatible with the TracSet platforms Workpiece Platforms max number without Prism 4 centering sleeves prisms Part no 200 x 300x 15 mm profile system mine _ ESTA Mam _ Special sizes on request Accessories for workpiece platform Part no Prism for workpiece platform MT46300 Travel direction Set of centering sleeves MT91811 Prism STANDARD DIMENSIONS Plattorm 200 x 300 mm single TRAC SPECIFICATIONS Net weight kg m 22 Platform 200 300 mm multiple 1957 max 5 prisms Section modulus Wx cm 27 Plattorm 200 400 mm single Section modulus Wy cm 10 8 Platform 300 x 400 mm single Moment of inertia Jx 230 Moment of inertia Jy 21 6 Plattorm 200 400 mm multiple m a ES Platform 300 400 mm multiple ER bal max 8 prisms Torsion tolerance mm m Straightness tolerance mm m Platform 200 x 550 mm single Material Aluminum nickel plated copper plastic Platform 300 x 550 mm single Nominal voltage IV DC 24 Current carrying capacity A 64 Platform 200 x 550 mm multiple Ambiance Temperature C 10 to 40 Plattorm 300 x 550 mm multiple Rel Air humidity 5 96 85 without condensation max 12 prisms Air purity level normal workshop ambiance Minimum requirement compatibility TracLink MT57949 36 MONTRAC MONTRAC 37 TRAC DIMENSIONS MECHANICAL LOAD C
60. ied directly trom the conductor rails LIFT The lift is used for the vertical trans port of Shuttles to solve the follow ing tasks connecting two or more systems with different working heights and feeding of Shuttles from a station to a ceiling system or vice versa 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 a counterpart locking points of the PositioningUnit TRACCONTROL COMPONENTS The TracControl components are used to control the route and the Shuttles of a Montrac system TRACSET The profile system convinces through cross product compatibility and flexibility The proven dovetail system allows for quick and easy assembly of all Montrac products MONTRAC 13 POSITIONINGUNIT PU 4 A PositioningUnit is used when the Shuttle is to be precisely positioned and or when the workpiece platform must be additionally supported dur ing the machining operation The PositioningUnit is available for single and multiple positioning 14 PROFITABILITY EFFICIENCY 300000 The latest development stage of the Euro Montrac system is particularly aimed at increasing its efficiency h f i i 250000 The power tor various components is Accumulated costs for conveyor belt system directly supplied
61. imes 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 below The dimensions shown in the drawings are minimum dimensions for which the manufacturer can guarantee trouble tree operation trouble tree operation CYCLE TIMES CYCLE TIMES Twin Axle Shuttle Twin Axle Shuttle Shuttle L 300 mm Shuttle L 400 mm Shuttle L 550 mm Shuttle L 550 mm Shuttle L 300 mm Shuttle L 400 mm Shuttle L 550 mm Shuttle L 550 mm LY 40 mm LU 160 mm LY 330 mm LU 330 mm ME 0 LU 225 qm 111 5 375 010 L 375 mm Additional load Additional load Additional load Additional load Additional load Additional load Additional load Additional load without max without max without max without max without max without max without max without max Passage at 5 5 5 5 5 5 5 5 Passage at 5 5 5 5 5 5 5 5 v 30 m min 2 1 2 3 2 3 2 6 26 2 9 247 2 9 30 m min 2 0 2 2 2 2 2 4 2 5 2 8 2 6 247 12 m min 4 2 4 5 4 8 Ds Sud 5 8 27 5 9 12 m min 4 0 4 2 4 4 4 6 22 5 4 5 4 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 pertorm a complete bypass with a single component The TracSwitch Arena is operated electrically and is powered directly from the conduct
62. in 110 rT O N l 11 min 300 TracSet Mounting Console MT57911 v y 7 MM f A 2S E y VI D 1 d 77 ai 7 N We 7 Wi m Z 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 77 40 66 40 511 55 40 LP 66 40 SLL 55 40 Wall Console MT57910 EXTENSION OPTIONS FOR ANTI FALL GUARD AND STOP Lift X Lift T MONTRAC 107 108 MONTRAC ACCESSORIES FOR LIFT TRACSUPPLY The switching cabinet is used for MONTRAC 109 Description Options Part no supplying the power rails of the R Connection Trac complete MT57463 Montrac transport system with 24 L Connection Trac complete MT57457 VDC Via these power rails the shuttles are supplied with their energy Anti Fall Guard MT52422 during the ride The output voltage is Box for anti fall guard MT57644 24 V DC short circuit proof and open circuit proof E The unit consists essentially of a Trac with damper MT57958 power supply timed on the primary TC1 IRM Basic with Y cable AB and A Cam MT56936 side contactors and fuse elements For operating it is equipped with a A and AB Cam Set MT90759 main switch an illuminated button Motor line 5 meters MT520319 for switching on
63. ith a selec tion 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 steps More infor mation to this can be found on pages 24 to 114 lt S O A cost free configura tor software is avail able for planning and E configuration of a Montrac o Ve system Complete production Uo lines can be easily configured with drag and drop commands and a 3D visualization with appropriate bill of materials is available immediately More informa tion to this can be found on pages 16 to 17 KO TracSet is a universal modular system for super structures and base frames of the Montrac sys tem lt offers a variety of possibilities The profile system allows for quick and easy installa tion without mechanical processing Le More information to this can be Oc found on pages 115 to 124 and The TracControl drive 2 control of the Montrac system can be designed CO according to individual requirements and provides flexible solutions for simple transport tracks up to complex pro duction 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 Pm E 21 MONTRAC
64. its can be assigned automatically Thus at the push of a button a correct material list can be generated TRACCONTROL 1 IRM DIMENSIONS Soen ADOTONMOBA TC T IRM Intelligent Routing Module TC1 IRM Basic with Y cable AB and A Cam 102 TC Basic Kit TC1 IRM MT56937 Box Single supply cable TC1 Curve kit TC1 IRM holder for signal generator Box Single supply MT56938 cable TC1 Double Module Kit TC1 IRM Holder for signal generator Box MT56939 Double supply cable TC1 Double Sensor Kit TC1 IRM 2 x holder for signal generator Box MT56940 Double supply cable 86 MONTRAC TRACCONTROL ACCESSORIES Proximity switch M4 PNP with cable and connector S8 Proximity switch M8 PnP pluggable Proximity switch holder A Cam straight A Cam complete L 21 44 mm B Cam AB Cam A and AB Cam Set Flag AB and A Cam Flag tor AB cam Flag tor B cam Flag A cam to PU 4 U Flag A cam to PU 4 GU Electrically switchable cam power off visible for shuttle Electrically switchable cam on power off invisible for shuttle Assembling jig for IRM ShuttleLock ACCESSORIES FOR TRACCONTROL 1 IRM TC1 IRM cabling L 1500 mm Cable tor TC1 IRM Box supply PC connection cable 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
65. l 2 the material flow can be controlled 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 TC1 IRM TC2 IRM are arranged along the Montrac monorail 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 autonomous and semi autonomous driven control elements can be mixed Simple Montrac system with TracControl 1 control OVERVIEW OF TRACCONTROL CONTROL VARIANTS Control Interfaces Central Variant Control elements control unit philosophy Hardware Protocol MDAC Montrac specific communication protocol based on UDP 20 MONTRAC TRACCONTROL 1 PositioningUnit Supolrac 2 D TC1 IRM Shuttle aT Oo EE montra TC1 IRM Shuttle TC1 IRM TC1 IRM HIGHER LEVEL eene 5 TracControl 1 is based on
66. l caster for support profile 159 Swivel caster for light profile 122 142 Abbreviation KEV 40 DEL 40 DEK 40 H55 40 5 40 GF 96 40 GFTP 66 40 GFLP 66 40 LRTP 75 40 LRLP 75 40 MONTRAC Part no MT46199N MT57446N MT57447N MT48310N MT45160N MT44019N MT54295N MT49397N MT54267N MT54269N 139 Page 159 160 160 161 161 162 162 162 163 163 140 MONTRAC OVERVIEW TRACSET COMPONENTS Figure Description HA KI Fixed caster for light profile Foundation anchor bracket Fixed caster for support profile Abbreviation BRTP 75 40 BRLP 75 40 FW 40 Part no MT54268N MT54270N MT46201N SUPPORT PROFILE TP 16 40 Page 164 164 165 MONTRAC 141 Precision aluminum rod extruded profile acc to DIN17615 hardened warm anodized natural end face cut nearly burr free SUPPORT PROFILE TP 16 40 SPECIFICATIONS Profile surface Section modulus Wy Moment of inertia Jy Length tolerance Torsion tolerance Straightness tolerance Weight Part no for length 2000 mm mm cm cm Eug Eug 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 143 LIGHT PROFILE LP 66 44 SUPPORT PROFILE TP 66 40 ZN
67. l concepts Montrac is the most flexible economic and reliable automation system for trans port tasks within a company intralogistics efficient assembly automation solu tions and systematic process interlinking of industrial production and logistics processes for automated manufacturing Innovative customers from different indus trial sectors automotive photovoltaics plastics medical optics batteries semi conductor technology food etc have benefited from the unique advantages for more than 15 years and use the Montrac system successfully around the world 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
68. lastic 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 Max load in axial direction Weight Part no ARTICULATED ARTICULATED ARTICULATED FOOT GF 96 40 poc FOOT FOR SUPPORT GFIP 66 40 FOR GFLP 66 40 FOR PROFILE TP 96 40 SUPPORT PROFILE LIGHT PROFILE TP 66 40 LP 66 40 kN 12 5 5 kg 0 865 0 350 0 400 44019 54295 49397 SWIVEL CASTER LRTP 75 40 LRLP 75 40 Swivel caster for light profile CASTER SPECIFICATIONS Max load in axial direction Weight Part no L 00 122 142 122 142 MONTRAC 163 Swivel casters each with corresponding adapter SWIVEL CASTER LRTP 75 40 FOR SUPPORT PROFILE TP 66 40 N 580 kg 0 465 MT54267N SYOVISAELL CAS TES LRTP 75 40 FOR LIGHT PROFILE TP 66 40 580 2210 MT54269N 164 MONTRAC FIXED CASTER 5 40 BRLP 75 40 19 Fixed caster for light profile FIXED CASTER SPECIFICATIONS Max load in axial direction Weight Part no 122 142 aan ee gt ON A 122 142 Fixed casters each with corresponding adapter FIXED CASTER BRTP 75 40 FORSUPPORT PROFILE TP 66 40 N 580 kg 0 375 MT54268N
69. lisions with obstacles or Trac is compatible with the TracSet other Shuttles profile system 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 TRACSWITCH The track switch 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 contined space The TracSwitch is operated electrically and is powered directly trom the conductor rails TRACSWITCH ARENA The TracSwitch Arena switch 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 SUPOTRAC The SupoTrac serves as a support for manual workstations In the SupoTrac 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 ERGOTRAC With the ErgoTrac a manual worksta tion can be set up more ergonomi cally The workpiece plattorm is tilted 25 towards the operator This makes the platform ergonomically more easily accessible and improves visibility TRACCROSSING The crossing makes it possible for two lanes to intersect each other at a right angle The electrical power is sup pl
70. lly loaded Twin Axle Shuttle kg V DC sec sec Nm A A N PC 12 Aluminum nickel plated copper steel brass plastic 24 min 228 max 20 9 Lx R9232 3 x DIN per position used 1 x DIN 4 x DOT per position used 1 x DOT 1 x Error 3x20 1 2 buf Site 40 2 9 340 10 to 40 5 96 85 96 without condensation normal workshop ambiance TracLink MT57949 TRACSWITCH DIMENSIONS Free space 150 mm A TS T NY ACCESSORIES FOR TRACSWITCH Configuration by montratec PC connection cable Flag for TracSwitch T base frame Double TracSwitch base frame H base frame Free space 150 mm Part no MT56935 DEEN MT57456 MT56584 MT56826 MT58230 MONTRAC Part no 49 MT58734 50 MONTRAC MONTRAC 51 OVERVIEW OF TRACSWITCH TYPES FREE SPACE FOR SHUTTLES WITH PLATFORM DIMENSIONS 200 X 300 MM 200 X 400 MM 200 X 550 MM 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 170 Depending on the load the free space will need to be increased upward TracSwitch Divide L TracSwitch Divide T TracSwitch Divide R Pos 1 IRM IRM Pos 1 4 f EE dimensions e HD sp E D ak Ali Imm 200x300 200x400 200x550 TRACSWITCH DIVIDE TYPES Pos 4 is equal to Pos turn
71. mm m kg m 67 37 82 37 82 tol 33 according to DIN 7168 medium 1 0 7 4 771 43207 3000 LOAD DIAGRAM N 4 F KeL 4 0 2 0 3 0 4 0 5 MONTRAC 145 F TP 16 40 x K 74 7 F TP 16 40 y K 48 9 Tl 228 LP 66 40 K 666 F TP 66 40 K 1302 d 96 40 K 3146 Example 1 Given 66 40 41 1 5 Result lins 738 N Example 2 Given TP 16 40 x F 90 Result ima Example 3 Given L 1m F 53500N Result LP 66 40 Profile 146 MONTRAC 147 ADAPTER PROFILE AP 40 40 MULTIPLE CABLE DUCT KFM 40 Precision aluminum rod extruded profile acc to DIN 7615 hardened warm anodized natural end face cut nearly burr free Designed for the production of adapters Precision aluminum rod extruded profile acc to DIN 7615 hardened warm anodized natural end face cut nearly burr free Designed for the production of adapters Precision aluminum rod extruded profile acc to DIN17615 hardened warm anodized natural end face cut nearly burr free Snapable profile for the laying of pneumatic hoses and electric cables ADAPTER PROFILE SPECIFICATIONS ADAPTER PROFILE ADAPTER PROFILE 40 40 56 40 Profile surface mm 21 600 Section modulus Wx cm3 2 2 1 04 Wy cm3 180 4 83 Moment of inertia Jx 0 14 0 67 273 18 53 according
72. ndividual aluminum profiles of the base frame The eye of the ground cable is fixed with the hexagon nut on the projecting thread shaft GROUNDING CONTACT ELEMENT AND GROUNDING ELEMENT SPECIFICATIONS GROUNDING CONTACT GROUNDING ELEMENT ELEMENT ERE 40 Use If electric cables with voltages gt 50 VAC or 75 V DC are laid directly on TracSet profiles the profiles must be grounded 6 SLL 12 40 50 20 40 The conversion kit applies to the following clamping elements 20 Weight kg 0 005 0 030 Part no MT55105 MT54960N TRACSET BASE FRAMES Appropriate base frames are avail able 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 MONTRAC MONTRAC 117 TRAC TABLE BOARD BASE FRAME TRAC SINGLE LEG SUPPORT BASE FRAME 652 of Shuttle platform Trac table board MT54819 Single leg support MT91565 TRACLINK TABLE BOARD BASE FRAME TRACLINK SINCLE LEG SUPPORT BASE FRAME 16 16 16 8 46 m of Shuttle
73. or rails Delivery options The TracSwitch Arena can be ordered at montratec mounted and ready configured according to the desired switch type 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 Material Nominal voltage Connections Rotation angle Rotation time 60 150 210 Torque of the rotary plate Current carrying capacity between the Trac connections on the movable Trac section Mechanical load capacity Ambiance Temperature Rel Air humidity Air purity level Minimum requirement compatibility corresponds to the weight of a fully loaded Twin Axle Shuttle kg IV DC sec Nm A A N PC Aluminum nickel plated copper steel brass plastic 24 lx 5222 3 x DIN per position used 1 x DIN 4 x DOT per position used 1 x DOT 1 x Error 20 22 60 0 5s 150 1s 210 1 5s 28 40 2 9 340 10 to 40 5 96 85 96 without condensation normal workshop ambiance TracLink MT57949 TRACSWITCH ARENA DIMENSIONS 465 3 537 3 ACCESSORIES FOR TRACSWITCH ARENA Configuration by montratec PC connection cable Base frame Free space Free space 150 mm 150 mm
74. orces for those special cases must be checked specifically 76 Part 65092 Part no MT65093 Part no MT65094 Part no MT65095 MONTRAC POSITIONINGUNIT MINIMUM TRAC LENGTH AU I L min Platform length mm Positioning Lmin mm 300 single 580 Platform length mm Positioning Lmin mm 400 single 840 300 multiple 840 Platform length mm Positioning Lmin mm 550 single 1290 400 multiple 1290 Platform length mm Positioning Lmin mm 520 multiple 1500 CYCLE TIMES IN SINGLE POSITIONINGUNIT SPU 4 380 420 480 520 630 670 MONTRAC 77 Running direction gt 80mm 120mm CYCLE TIME IN SINGLE POSITIONINGUNIT SPU 4 Cycle time Fi du Shuttle 3 Twin Axle Shuttle with with maximum load 5 maximum load s Platform L 300 mm 2 90 Platform L 400 mm Platform L 550 mm 3 34 3 95 Time measurement with maximum load Cycle time Shuttle MSH 4 Twin Axle Shuttle with Cycle time Shuttle MSH 4 5 maximum load 5 2 80 3 00 320 3 20 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 l
75. pen routing In the Montrac transport system 10 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 Trac NN Curve is identical to the Trac AAA 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 60 2 TracCurve 90 2 TracCurve 90 8520 TRACCURVE SPECIFICATIONS 90 R220 45 R220 GER 45 R520 Net weight kg 22 1 4 5 0 2 8 Material Aluminum nickel plated copper plastic Nominal voltage V DC 24 Current carrying capacity Al 64 Length tolerance mm 205 Ambiance Temperature Ka 10 to 40 Rel Air humidity 5 96 85 96 without condensation Air purity level normal workshop ambiance Minimum requirement compatibility TracLink MT57949 42 MONTRAC MONTRAC 43 TRACCURVE 90 R220 DIMENSIONS TRACCURVE 90 R520 DIMENSIONS TracCurve R520 Part no TracCurve R220 Part no Patno 90 R520 inside conductor rail MT58201 90 R220 inside conductor rail MT56095 90 R220 outside conductor rail MT56096 90 R520 outside conductor rail 58207 Accessory tor TracCurve 90 R
76. pping accuracy over n Shuttles Running speed v8 Reduced running speed Increased max speed for defined sections Supply voltage Power consumption during standstill at Vmax 30 m min at Vmax 55 m min when accelerating Acceleration time unloaded 30 m min with max add load Cycle time with max add load Sound pressure level Ambience lemperature Rel Air humidity Air purity level Minimum requirements compatibility 1 Weight of Shuttle plate load capacity on page 31 mm kg mm m min m min m min V DC A A A A sec sec sec ABA PC MONTRAC 29 Shuttle Shuttle Shuttle Twin Axle MSH 4 MSH 4 MSH 4 Shuttle MSH 4 Le 00200111 oo0 ma b 11 343 443 599 973 S55 9 9 8 8 20 20 20 38 30 12 99 24 max 30 0 1 0 1 0 1 0 15 0 7 0 7 0 7 1 6 1 1 1 1 8 2 1 2 2 1 CN 0 5 95 2 8 3 0 3 2 3 2 10 to 40 5 96 85 96 without condensation normal workshop ambiance TracCurve starting from serial no 695586 XXX TracSwitch starting from serial no 722157 XXX TracSwitch Arena starting from serial no 691469 XXX Communication module OSM3 TC1 IRM or TC2 IRM 30 MONTRAC MONTRAC 31 SHUTTLE MSH 4 DIMENSIONS SHUTTLE MSH 4 LOAD LIMITS 9 300 400 550 34 170 2 0 420 The center of gravity of the load should be centered and not higher than 130 mm above the Shuttle For more intormation see operating manual of Shuttle MSH 4
77. rmation about the components of the TracSet please refer to chapter TracSet starting on page 133 38 MONTRAC TRACLINK The TracLink is the connecting ele ment between two Trac sections or active components e g TracSwitch This element provides the electrical connection for the conductor rails and allows for thermal expansion The power supply to the system is also performed by TracLink With the built in connection the GND conduc tor rail is connected to the potential of the TracLink aluminum body TRACLINK SPECIFICATIONS Net weight Material Nominal voltage Current carrying capacity Ambiance Temperature Rel Air humidity Air purity level Minimum requirement compatibility kg IV DC A PC 0225 Aluminum copper steel brass plastic 24 64 10 to 40 5 96 85 96 without condensation normal workshop ambiance Trac MT56926 XXXX TRACLINK AND POWER SUPPLY CABLE DIMENSIONS For power supply optional with cable and cable mounting ACCESSORIES FOR TRACLINK Power cable 10 m Power cable 30 m TracLink table board base frame TracLink single leg support TracLink TracLink double leg support TracLink Trac double leg support TracLink 3 leg support 60 49 40 Part no MT57577 11272213 MT57431 MT56817 MT58298 MT58299 MT57948 MONTRAC MT57949 2 40 MONTRAC 41 TRACCURVE TRACEND DIMENSIONS end piece with o
78. roke ip m 0 45 0 6 travel time ls Travel time of lift with up to 34 kg load stroke x 0 9 V A M 2 travel time s Travel time of lift with up to 34 kg load stroke gt 0 9 m 41 2 travel time s Travel time for cycle 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 LIFT SPECIFICATIONS Net weight basic construction kg 5 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 125 acceleration with 17 kg load m s 5 Max acceleration with 34 kg load m s 235 Max positions 7 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 lt 66 Operating temperature of motor PC 65 102 MONTRAC LIFT DIMENSIONS Lui Yl ON Bc i HI UN l EN oOo Ur 5 Y Y d JE c DD Kr Bl 25 20 00 0 de 5 Ze S 2 CT 2 O mn E E 2 1 69 5 ek O 4 4 o gt 1 Stroke in example diagram 1000 mm shuttle platform top edge 900 mm Please state lower position and maximum stroke when pl
79. ruc tural framesto be subsequently reinforced vertical supports horizon tal bars diagonal struts All the clamping screws in the struc tural framing are always accessible The base frames are easy to disas semble at a later time for reuse thanks to the clamping connections no drill holes are necessary MONTRAC 135 vibration proof precise accessible angle adjustable vertical diagonal can be subjected to high loads reusable 136 TRACSET COMPONENTS OVERVIEW Figure Description Support profile Z Light profile Support profile Support profile Adapter profile lt Adapter profile Multiple cable duct Fixed screen profile Covering cap 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 MT42852N3000 MT43207N3000 MT41258N2000 MT46253N2000 MT45229N2000 MT45159N2000 Gray MT48619 Gray MT61163 Blue MT61113 OVERVIEW TRACSET COMPONENTS Page Figure 141 142 143 144 146 146 147 148 149 149 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 longitudin
80. s 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 free 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 clean room Thanks to an improved development it has now been certified by the Fraunhofer Institute for production in clean room class 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 any time Montrac con sists 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 Montrac configurator software The monorail track system is defined w
81. se the UDP based MDAC protocol Montrac specific protocol is used The interface allows a guide system to control and monitor the Montrac system The TC2U can communicate with external control elements using 1 signals in the same way as the TracControl 1 TC2U CONFIGURATION The WebGUI available on the TC2U with which all modules and the TC2U are configured can be easily called up using any web browser A 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 mainte nance 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 Net weight without plug in boards Length Input voltage Current consumption at 24 V DC Min input voltage inputs Max input voltage inputs Current consumption per input Output voltage outputs Max outputcurrent per digital output Max output current per 1 board Max outputcurrent per TC2U Material Type of protection Ambiance Temperature Rel Air humidity Air purity level
82. terial 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 127 128 MONTRAC PNEUMATIC LIFT The pneumatic lift allows the vertical transport of the Shuttles This compact and space saving lift is easy to operate and has been espe cially 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 24 V 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 A transport belt adapted to the requirements is mounted on the transport belt Th
83. th 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 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 TracCo ntrol 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 vmin Max weight Shuttle weight without plattorm Static moment around the longitudinal axis Supply voltage Power consumption during standstill at Vmax when accelerating Accelerating time unloaded with max add load Sound pressure level dBA Ambience lemperature 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 A A A sec sec PC Twin Axle Shuttle 3 rear axle empty Shuttle 3 300 400 550 550 DO 221110 30 30 Z 12 17 L 3 8 4 1 4 6 6 2 27 lt 4 24 24 0 08 0 08 0 80 0 80 2 24 2 24 0 85 0 85 1 40 1 40 27 10 to 40 5 96 85 96 without condensation normal workshop ambiance Twin Axle Shuttle 3
84. the supply and a i omes MT520320 button for switching off the supply 20 The cabinet can also be switched E and off via PLC The component is Return system line 5 meters MT520322 available in two capacities one with 10 meters MT520323 40 ampere and one with 2x 40 Pese MT520324 ampere output current In order to guarantee that never more than the Return system line 10 meters MT57470 allowed 40 ampere are connected to 15 meters MT57614 the rail system the plant must imper 20 meters MT57615 atively be divided into sections by ing Isolation i Supply cable wire number 7 for 24 V DC 10 meters MT520360 10000 EE Wie stronger system version Supply voltage servo control connection 15 meters 520360 15000 and external control 20 meters MT520360 25000 on the power of the switching cabinet 2 wire supply cable for Trac power supply 10 meters MT520361 10000 required tor a plant 15 meters MT520361 15000 TRACSUPPLY SPECIFICATIONS 20 meters MT520361 25000 Litt Control Set MT58562 40 A power supply 2 x 40 A power supply Control cabinet MT58558 24 axles 48 axles Control cabinet MT58560 Input voltage IV AC 3 x 400 Keypad XT operating module min 1 per system 1520325 Mainstrequency Hz 5 0 4010 PC USB system bus adapter if required MT520326 Input voltage range V AC 380 500 Profibus bus module if required MT520445 Frequency range Hz PC system bus adapter RS 232 if required MT520393 Switch on current
85. through the conduc E ec Accumulated costs for Montrac system tor rail so very little cabling is required With the Chaos Technology the control effort is reduced or totally M T 150000 eliminated Local control modules communicate with the Shuttles and control the line autonomously 100 000 50000 0 Project planning Cabeling Valves Montage Software Pallet Nr Line cost Maintenance 6 y 6 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 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
86. tle and TC1 IRM communi cate with each other via signals in the infrared spectrum The TC1 IRM can function as a communication interface between the rail system and the master control or as a control element operating autonomously The communication between the master control and the IRM takes place via I O at pre detined connector pins or via the serial interface on the TC1 IRM TracControl 1 components are not compatible with TracControl 2 components as a different transmis sion protocol is used for the Trac Control 2 TRACCONTROL 1 IRM SPECIFICATIONS Power supply Power consumption Max load current Connections Dimensions Net weight Ambiance Temperature Rel Air humidity Air purity level Minimum requirement compatibility V DC mA A mm g ES 24 25 with 24 V DC 1 with 24 V DC outputs short circuit proof 2 identically configured 10 pin JST connectors 165232 3 DIN 3 X DOT 102 x 36x 11 length x width x height 33 10 to 40 5 96 85 96 without condensation normal workshop ambiance 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
87. to DIN 7168 according to DIN 7168 Length tolerance medium medium Straightness tolerance mm m 0 27 Length tolerance according to DIN 7168 medium Weight kg m 0 732 1 620 Weight kg m 0 549 Part no for length 2000 mm MT41258N2000 MT46253N2000 Part no for length 2000 mm MT45229N2000 148 MONTRAC MONTRAC 149 FIXED SCREEN PROFILE FFP 40 COVER CAP AK 16 40 AK 66 40 AK 96 40 Precision aluminum rod extruded profile acc to DIN17615 anodized natural end face cut nearly burr free Lid of ABS plastic to close off the TP support profiles COVER CAP AK 16 40 AK 66 40 AK 96 40 FIXED SCREEN SPECIFICATIONS Bie Length Tolerance according to DIN 7168 medium Part no for AK 16 40 for TP 16 40 MT48619 Weight kg m D 570 Part no for AK 66 40 for TP 66 40 or LP 66 40 MT61163 MT61113 Part no for length 2000 mm MT45159N2000 Part no for AK 96 40 for TP 96 40 MT48618 150 MONTRAC CLAMPING ELEMENT LONGITUDINAL LONGITUDINAL SLL 55 40 CLAMPING ELEMENTS SPECIFICATIONS Resistance to misalignment of two joining protiles Torque value of screw s Parallelism of clampedsurfaces Weight Part no N mm kg in clamped state in clamped state For connection of dovetail profiles under high load For connection of dovetail profiles under medium load CLAMPING ELEMENT CLAMPING ELEMENT LONGITUD LONGITUD LONGITUD LONGITUD SLL 55 40 SLL 20 40 3000 1380 6 6 0 02 0 0
88. 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 TracControl 1 IRM 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 TheTC1 IRM 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 Shu
89. ts of the TracSet please reter to chapter TracSet starting on page 133 E m 170 maso woo CO wm um us Platform dimensions 300 400 550 400 550 55 ale SEKR k pw s EE EIN 48 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 contined space The TracSwitch is operated electri cally and is powered directly from the conductor rails Delivery options The TracSwitch can be ordered at montratec readily mounted and contigured 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 Contigurator can be downloaded from the website www schmid group com TRACSWITCH SPECIFICATIONS Net weight Material Nominal voltage Connections Rotation angle Rotation time 120 Rotation time 240 Torque of the rotary plate Current carrying capacity between the Trac connections on the movable Trac section Mechanical load capacity Ambiance Temperature Rel Air humidity Air purity level Minimum requirement compatibility corresponds to the weight of a fu
90. ttle 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 system 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 identifi cation 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 ensur
91. us 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 differ ent ascent angles are possible 11 wgl UD pons gt MONTRAC L 132 MONTRAC SCALES MODULE The scales module consists of a SupoTrac with integrated high preci sion 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 od a Profibus interface This module is especially used in the intralogistics and also for assembly processes as check weigher TRACSET TracSet is a patented assembling system with cross product compat ibility and flexibility Its proven dove tail 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 displace ment for the two
92. x without max without max 5 5 5 s s s s s 1 7 1 9 2 0 22 2 9 2 6 2 4 2 3 6 4 0 4 4 4 4 8 Se 5 0 5 4 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 contigured The configuring of the unconfig ured 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 Material Nominal voltage Connections Rotation angle Rotation time 90 Torque of the rotary plate Current carrying capacity between the Trac connections on the movable Trac section Mechanical load capacity Ambiance Temperature Rel Air humidity Air purity level Minimum requirement compatibility corresponds to the weight of a fully loaded Twin Axle Shuttle kg IV DC sec Nm A A N PC 2 Aluminum nickel plated copper steel brass plastic 24 1 x R5232 2 x DIN per position used 1 x DIN 3 x DOT per position used 1 x DOT 1 x Error 90 1 4 30 40 2 5 340 10 to 40 5 96 85 96 without condensation normal workshop ambiance TracLink MT57949 TRACCROSSING DIMENSIONS ACCESSORIES FOR TRACCROSSING

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