Power & Free Systems

Maximum Performance. Fully Automated. Adaptable.

Flexible and customizable Power & Free systems

Our Power & Free systems enable independent, cycle- and position-independent transport of workpieces. They are ideal for complex manufacturing processes, variant production, or parallel production lines. These systems feature numerous components that allow for a three-dimensional track layout and are combinable. Their modular design facilitates easy integration into existing facilities.

This enables the connection of different system circuits, such as work and speed zones. Consequently, even with continuous conveying within a single system circuit, material flow with freely selectable cycle times is achieved.

For heavy-duty applications with a load capacity of 500 to 13,000 kg, we offer high-performance system solutions for manual or fully automated operation. Engineered for the most demanding requirements in production and intralogistics, our systems combine robustness with intelligent control technology.

Extensive expansion options allow the system to be precisely tailored to your processes. The result: maximum stability, seamless integration into complex manufacturing processes, and maximum process control – even under extreme loads.

System Overview

A Power & Free system is a combined, partially automated conveyor technology system type, consisting of a driven main track ('Power') and a co-moving load-carrying track ('Free').

These systems enable flexible, accumulation-capable, 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

System Components

Driven power track sections
Free-running track section for trolleys (Free-Track)
Carriers and stoppers (decoupling devices)
Accumulation, lifting, and stopper elements
Switches and distribution systems
Load handling attachments such as hooks, traverses, or product carriers
Control and safety technology.

The loads are supported by the Free-Track, while the Power-Track transmits motion via carriers or pawls.

System Functionality

The Power-Track is driven continuously or intermittently. The Free-Track, carrying the load carriers, is connected to the Power-Track via coupling mechanisms.

Basic Functions

Carrying: The carrier engages the trolley or transport unit and conveys it.
Decoupling / Accumulating: Stoppers or decouplers disengage the trolley from the drive. The transport unit halts, while the Power-Track continues its operation.
Switching and Distribution Functions: Transport trolleys can be automatically directed into side lines, buffers, or alternative routes.
Lifting and Lowering: Depending on the system, this is achieved via lift units, lift/lower stations, or lifting modules.

System Advantages

Parallel operation of multiple transport trolleys
Buffering and asynchronous operation
Individual process times per station
Automatic or semi-automatic control
Targeted stopping at defined stop points

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

Automatic Operation

The material flow is entirely managed by the system control.

Automatic engagement and decoupling
Automatic diverting
Indexed and accumulable operation
Automatic lifting and lowering processes, where applicable
Process monitoring via sensor technology

The operator remains outside the hazardous area.

Manual Operation / Interventions

Manual operating modes are utilized for:

Maintenance and servicing
Cleaning operations
Manual release of individual carriers
Positioning for inspections

Typical Functions

Manual switchover of diverters, where provided
Manual release or stopping of individual carriers
Manual advancement in a de-energized state

Fault Operation

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

Safety Instructions

Power & Free systems are safe installations when operated in accordance with their intended purpose. The following rules must be strictly adhered to:

Access to hazardous areas is restricted to authorized personnel.
Loads must not be manually touched or stabilized while the carrier is in motion.
The load capacity of carriers and suspensions must not be exceeded.
During manual intervention, the drive must be safely de-energized and secured against accidental re-engagement.
No personnel are permitted under suspended loads.
Diverter areas, stoppers, and drive zones must not be entered during operation.
Loose objects, clothing, or body parts must not become entangled in the machinery.
Malfunctions may only be rectified by qualified personnel.

Particular caution is required in switch areas, stopper zones, buffer sections, and around all moving mechanisms.

Loading and Suspending the Load

Ensure that the load carrier is freely accessible.
Secure the load handling attachment according to specifications.
Verify that the load is centered and securely suspended.
Await carrier release by the control system, if applicable.

Transport in Automatic Mode

The transport trolleys are automatically conveyed by the power chain.
At switches, the direction is automatically determined by the control system.
Speed and cycle timing are determined by the system.
The operator only monitors the process and must not intervene with moving mechanisms.

Transport in Manual Mode

Only move transport trolleys when the system has been safely shut down.
Only reposition switches when they are released and unloaded.
Execute movements slowly and in a controlled manner.

Depositing or Unloading the Load

Stop the load at a lowering or retrieval station, or allow it to uncouple automatically.
Release or remove the load attachment.
Return transport trolleys to the parking or initial position.

Special Notes

When handling heavy or bulky loads, wearing personal protective equipment is mandatory.
Stoppers, drivers, switches, and sensor technology must be regularly checked for proper function.
The operation of the system must not be altered or manipulated.
In buffer areas, multiple carriers may be queued – sufficient clearance from moving loads must be maintained.
In the event of unusual noises, erratic operation, or blockages, the system must be immediately taken out of service.
Loads may only be picked up or deposited in designated areas.
Vehicles must not remain permanently in accumulation zones unless specifically designated for such purpose.
During operation, switches must not be actuated manually.
Particular caution is warranted in the vicinity of drives and tensioning stations.
Modifications to the control system or mechanical structure are only permissible with manufacturer approval.

Maintenance and Inspection

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

Visual inspection of rails, chains, and drive components.
Inspection of drive dogs, coupling mechanisms, and stoppers.
Functional testing of all switches and lift units.
Verification of control components and sensor technology.
Retensioning or lubrication of chains and bearings according to manufacturer specifications.
Inspection of load carriers, hooks, and suspensions.
Documentation of all maintenance and inspections.

Technical Note

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