Use Case — Intralogistics

Monorail – Seamless Control for Monorail and Suspended Rail Systems

R3 Solutions provides the wireless technology that controls monorail and suspended rail systems without failures, with minimal wear, and reliably along the entire route—even in harsh 24/7 production environments.

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Overview

Monorail and overhead monorail systems transport workpieces along fixed routes through the production facility. In most cases, they cover long distances around the clock. They are standard in many industries—from automotive and component manufacturing to paint shops and assembly lines—because they keep floor space clear and enable a predictable, consistent flow of materials.

Control is crucial to ensure that such a system supports production rather than slowing it down. Traditionally, data transmission relies on sliding contacts or busbars. These mechanical systems are subject to wear, require maintenance, and are not always feasible in practice. A wireless control system overcomes these drawbacks but must achieve the same level of reliability as a wired connection.

Typical Challenges in the Industry

Wear in Mechanical Transmission Systems

Slip rings and busbars wear out, incur ongoing maintenance costs, and are a common source of downtime. A wear-free wireless solution permanently reduces maintenance costs.

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Uninterrupted availability during continuous operation

Monorail systems often operate 24/7. Even brief communication outages can bring the entire production line to a halt—resulting in high follow-up costs.

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Control over long distances

The connection must function reliably over the entire length of the track, even if it extends for hundreds of meters through the hall.

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Real-time-capable control system

The positioning, routing, and process timing of the conveyor belt require deterministic, delay-free data transmission to the central control system.

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Feasibility: Where Cables Reach Their Limits

Especially when retrofitting existing systems, continuous wired data transmission is sometimes structurally impossible or only possible with great effort.

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Easy integration into the existing control system

The wireless solution should integrate seamlessly into the existing PLC and protocol environment without interfering with the higher-level control architecture.

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How R3 Solves These Challenges

The R3 product portfolio is tailored to the requirements of rail-based conveyor systems, such as real-time, deterministic control and wear-free, low-maintenance connections along the entire route length.

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For safety and control applications with real-time requirements and high synchronization.

  • Determinism: Time-slot-based signal transmission, packet loss rate of 0.000000001 %.
  • Real-time communication: Latencies of up to 2 milliseconds are possible.
  • Safety-compliant: PROFIsafe, CIP Safety, and others are transmitted transparently.
  • Proven in practice: Years of use by European and American OEMs.
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Typical Project Workflow

Project Assessment

Project analysis, functional safety requirements, protocol selection.

Network Solution Plan

Traffic analysis, channel planning, configuration details.

Deployment

Installation, functional safety testing, acceptance testing.

Support & Maintenance

Monitoring, firmware updates, and enhancements.

Success Stories

Maintenance-free wireless control of turntables for hose production

Turntables are a special case in automated production. Due to their rotational movements, the use of cable connections is virtually impossible. Sliding contacts are an alternative, but they often result in downtime. The obvious solution is therefore control via a wireless network.

Read Success Story

Wireless Robot Control for Auto Body Shops

In auto body manufacturing, robots equipped with grippers perform key work steps. The gripper control system relies on cables and connectors that are subject to regular wear and tear. If these fail during continuous operation, the system comes to a standstill, resulting in enormous follow-up costs.

Read Success Story

Wirelessly Controlled Monorail System

A Canadian automotive supplier operates a monorail suspension system at its plant in the U.S., which plays a key role in ensuring smooth production and logistics. The control system for this system was to be implemented via radio.

Read Success Story

Daniel Thiel

Wireless Solutions Expert

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