Power & Free systems

Maximum performance. Fully automated. Customizable.

Flexible and Customizable Power & Free Systems

Our Power & Free systems enable the independent transport of workpieces, regardless of cycle time or position. They are ideal for complex manufacturing processes, variant production, or parallel production lines. These systems feature numerous components that allow for three-dimensional routing and can be combined with one another. Their modular design allows for easy integration into existing facilities.

This allows different system circuits—such as work and speed zones—to be interconnected. As a result, even during continuous material flow within a system circuit, cycle times can be freely selected.

For heavy-duty applications with load capacities ranging from 500 to 13,000 kg, we offer high-performance system solutions for manual or fully automated operation. Designed to meet the most demanding requirements in production and intralogistics, our systems combine durability with intelligent control technology.

With a wide range of expansion options, the system can be tailored precisely to your processes. The result: maximum stability, seamless integration into complex manufacturing processes, and optimal process control —even under extreme loads.

System Overview

A Power & Free system is a combined, partially automated conveyor system consisting of a powered main track (“Power”) and a load-carrying track that moves along with it (“Free”).

The systems enable flexible, buffered, and individually controllable transport of loads.

Typical applications

Painting systems
Assembly and production lines
Intralogistics and transport routes
Buffer and storage areas
Material handling systems with variable cycle times

Components of the system

powered track sections
Free-running rail for trolleys (Free-Rail)
Drivers and stoppers (decoupling devices)
Check, lift, and stop elements
Switches and distribution systems
Lifting accessories such as hooks, spreader beams, or load carriers
Control and Safety Technology

The loads are carried by the free strand, while the power strand transmits motion via sprockets or pawl mechanisms.

How the system works

The power train is driven continuously or intermittently. The free train with the load carriers is connected to the power train via coupling mechanisms.

Basic functions

Conveyor: The conveyor engages the carriage or transport unit and moves it along.
Disengagement / Backstopping: Stoppers or disengagers disconnect the carriage from the drive. The transport unit comes to a stop, while the power train continues to run.
Switching and routing functions: Transport carts can be automatically routed to sidings, buffer stops, or alternative routes.
Lifting and lowering: Depending on the system, this is achieved using lift units, lifting/lowering stations, or lifting modules.

System Benefits

Simultaneous operation of multiple transport carts
Buffering and clock offset
Individual processing times per station
automatic or semi-automatic control
Stopping at specific stops

The system is designed for buffered and flexible material flows with individually controllable process steps.

Automatic mode

The material flow is fully managed by the system control.

Automatic coupling and uncoupling
automatic point switching
Pulsed and buffered operation
automatic lifting and lowering processes, if available
Process monitoring using sensors

In this case, the operator is outside the danger zone.

Manual operation / manual intervention

Manual modes are used for:

Maintenance and Repair
Cleaning work
manual triggering of individual carriers
Positioning for Inspections

Typical features

manual point switching, if provided
manually start or stop individual carriers
Manual movement when the power is off

Fault mode

controlled shutdown of the system
Troubleshooting performed by trained personnel in accordance with the manufacturer's specifications
Manual movement or removal of carriers only after authorization and securing

Safety Instructions

Power & Free systems are safe when operated as intended. The following rules must be strictly observed:

Access to hazardous areas is restricted to authorized personnel.
Loads must not be touched or stabilized manually while the carrier is in motion.
The load capacity of the carriers and mountings must not be exceeded.
When performing manual operations, the drive must be safely shut down and secured to prevent it from restarting.
No one is allowed to stand under suspended loads.
Do not enter switch areas, stopper zones, or drive zones during operation.
Loose objects, clothing, or body parts must not get caught in the machinery.
Faults may only be repaired by qualified personnel.

Special caution is required in switch areas, buffer zones, and buffer sections, as well as near all moving mechanical parts.

Lifting and securing the load

Make sure the product carrier is easily accessible.
Secure the load-bearing equipment according to the instructions.
Check that the load is centered and securely attached.
Wait for the controller to release the carrier, if available.

Transport in automatic mode

The transport carts are automatically pulled along by the power conveyor.
At switches, the direction is automatically set by the control system.
Speed and cycle time are determined by the system.
The operator only monitors the process and does not interfere with moving parts.

Manual transport

Move the transport cart only after the system has been safely shut down.
Do not switch points unless they have been cleared and are free of load.
Perform movements slowly and in a controlled manner.

Setting down or unloading the load

Stop the load at the lowering or unloading station, or have it automatically disengaged.
Release or remove the load.
Return the transport cart to its parking or starting position.

Special Notes

When handling heavy or bulky loads, wearing personal protective equipment is mandatory.
Stoppers, drivers, switches, and sensors must be checked regularly to ensure they are functioning properly.
The operation of the system must not be altered or tampered with.
In buffer zones, multiple carriers may be positioned one behind the other—sufficient distance from moving loads must be maintained.
If you hear unusual noises, notice irregular operation, or encounter blockages, shut down the system immediately.
Loads may only be loaded or unloaded in designated areas.
Vehicles must not be parked in traffic congestion zones on a permanent basis unless specifically permitted to do so.
Switches must not be operated manually during operation.
Special care must be taken when working with drives and clamping stations.
Modifications to the control system or mechanical structure are permitted only with the manufacturer's approval.

Maintenance and Inspection

Regular inspections ensure safe and reliable operation. Typical maintenance tasks include:

Visual inspection of rails, chains, and drive components
Inspection of drive elements, clutch mechanisms, and stops
Functional testing of all switches and lift units
Inspection of control components and sensors
Tensioning or lubricating chains and bearings according to the manufacturer's instructions
Inspection of product carriers, hooks, and hangers
Documentation of all maintenance and inspections

Technical Note

All maintenance and repair work must be performed by qualified personnel .