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Transfer Car Modernization
11/18/2021
High-quality, cost-effective solutions that can be easily retrofit to any existing transfer car equipment with minimal downtime and an emphasis on safety
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When it is time to modernize your legacy transfer car equipment, you can typically anticipate costly replacements and long periods of downtime that will negatively affect your bottom line. Our engineers felt this was unacceptable and developed the "new normal" in transfer car modernization solutions with an impressive suite of products.
Below you will find high-quality, cost-effective solutions that can be easily retrofit to any existing equipment with minimal downtime and an emphasis on safety.
Nexus BB + Optical Positioning:
The one-of-a-kind, patented Nexus BB is the only industrial data over power solution on the market. Nexus BB turns your conductor into the most secure and reliable Ethernet connection and is easily retrofit to existing systems, including; festoon, cable chain, slip ring, conductor rail, and cable reels. So, when Wi-Fi falls short, Nexus BBs secure hardwired connection prevails as the only solution for industrial network communication.
Pairing Nexus BB with Optical Positioning will offer a complete solution for positioning needs along a fixed rail. Using an optical camera to read code tape, Optical Positioning allows automated machinery to determine the exact position of moving machines or elements, allowing for safe vehicle spacing, material storage location, and position feedback. Our Optical Positioning systems are easy to quote, quickly retrofitted into existing applications, are compatible with PROFINET, EtherNET/IP, and PROFISafe, and are easy to install.
Jay Radio + RadioSafe Global Safety Stop:
The final step in our modernization solutions is with the addition of Jay Radio + RadioSafe Global Safety Stop. Jay Radio is our cost-effective, SIL 3 safety-rated bidirectional radio solution engineered to provide higher productivity through precise maneuvering. When you pair Jay with our RadioSafe Global Safety Stop, all machines can be halted with the push of a button, adding an additional safety layer in machine-to-machine communication.
Are you looking for a complete modernization overhaul?
Replace your existing system with our reliable, high-capacity Hevi-Bar II Conductor Bar system. Hevi-Bar II is low maintenance, easy to configure, installs fast, and has versatile mounting options. Hevi-Bar II is genuinely our "install it once and forget about it" conductor bar system.
Relevant Products
Nexus BB Powerline Communication System
Additional information
Nexus BB is a brand new data over power solution for industrial applications, and works across many different conductor profiles including; festoon, cable chain, slip ring, conductor rail, and cable reels. Nexus BB creates a secured hardwired PLi-Fi (Power Line-Fidelity) connection through any conductor providing ultimate reliability. The secure signal travels through two of the power conductors, eliminating the need for additional signal conductors.
Nexus BB can be used on new and existing systems to add a secure data communication layer, and does not require any networking expertise or special equipment. Nexus BB replaces Wi-Fi with PLi-Fi for mobile equipment communication, with the same minimal maintenance as a WiFi solution. The innovative design adapts to noisy environments for dependable performance. Nexus BB is a plug and play solution that allows for easy modernization to existing installations with minimal downtime. Nexus BB is a data over power solution that provides a contained PLi-Fi signal for ultimate security through signal isolation.
Learn more about Nexus BB with our videos on YouTube
Downloads
Optical Positioning System
Additional information
Material handling systems, automated overhead cranes, and other automated machinery often need an accurate way to determine the exact position of the moving machines or elements. You can use this information to assure correct vehicle spacing, provide material storage locations, or to give position feedback. The Conductix-Wampfler Optical Positioning System (OPS) offers a complete solution to supply the needed position information along a fixed rail. You can integrate our OPS into new installations or easily retrofit it onto existing applications.
Product data
The Optical Positioning System:
- Provides a complete system solution for conductor bar mounting
- Installs easily in either new or existing bar systems – no special tools required
- Meets PROFINET, EtherNet/IP, and PROFIsafe protocols
Downloads
Beta / Beta ATEX Radio Remote Control
Configuration Tool Additional information
The Beta radio remote control operator module adapts to your application to make your process more efficient. This easy-to-use light-weight handheld module gives you incomparable freedom of movement, precise and agile quality maneuvers and higher productivity while ensuring your operators’ safety.
Main Features:
- Configurable, interactive 2-way radio link to exchange information while adapting to the radio environment
- User-friendly screen for look-up, selection, validation, configuration…
- Compact, easy-to handle casing for one-hand control
- Quick and easy setup for application configuration thanks to iDialog software (labels, feedback, alarms, mapping actuators/outputs, interlocks, network features, access by PIN codes)
- Easy to maintain thanks to its diagnostic aid system (information on screen, iDialog analysis software)
In grey ATEX version, it will even operate safely under permanent risk of explosion (gas: zone 0, dust: zone 20).
Product data
Fully compliant with safety and security standards:
ATEX manufacturer 2014/34/EU
EC type certificate issued by LCIE
Machinery directive 2006/42/EC:
Emergency stop
- SIL 3 per EN 61508
- Performance level PL e per EN ISO 13849-1 and -2
EC type certificate issued by TÜV NORD
Radio and telecommunication terminal equipment:
(low voltage, electromagnetic compatibility, radio spectrum)
FCC part 15
ARCEP certificate
Radio Equipment Directive (RED)
Frequency selection manual / automatic:
- 64 frequencies for 433-434 MHz
- 12 frequencies for 869 MHz
- 64 frequencies for 911-918 MHz
Downloads
Safety Radio Remote Controls | Technical Installation and User Manual
Technical Installation / User Manual
Global Safety Stop System for Radio Remote Controls
Additional information
The Global Safety Stop System for Radio Remote Controls focuses on SIL 3 – PLe wireless emergency stop to tackle critical dangers typically met in highly automatized factories / warehouses, robotized production cells, continuous process lines.
Global safety:
- Much more than individual machine safety
- SIL 3 - PLe TÜV Süd certified solution
- Independence from any navigation solution
- Operators absolute safety within fleets of AGVs
Product data
Outputs:
- Opto-coupled 100 mA static output: 6 function outputs
- Safety relays: 2 safety relays with 3 NO guided contacts
The front plate is removable for configuration.
Radio Characteristics:
Characteristics compliant with ETS 300 220
Frequency:
64 frequencies programmable in 433-434 MHz
Antenna:
1/4 wave, as accessory, plugs in to BNC connector
Sensitivity:
< -100 dBm
Downloads
Hevi-Bar II Conductor Bar
Additional information
The Conductix-Wampfler Hevi-Bar II Conductor Bar System delivers the kind of reliable, high-capacity crane rail electric service needed by factories, mills, storage yards, people movers, and other rigorous applications.
Hevi-Bar II features:
- Effective Heat Dissipation - uses surface area rather than mass to dissipate heat generated by high current conditions
- Mounting versatility - can be mounted with the bars next to one another (horizontal) or one above the other (vertical)
- A choice of Insulating Covers - standard orange PVC, green PVC for the bonding (ground) conductor bar (500 amp only), black UV-resistant PVC for outdoor use, and medium or high heat versions to withstand higher ambient temperatures
- Ease of Installation - a limited number of modular components
- Low Maintenance and Long Life - this is truly an "install it once and forget about it" conductor bar system
- Easy System Configuration - using our advanced "Quick Quote" software!
Product data
Current Capacity Range:
500 amps, 700 amps, 1000 amps, and 1500 amps, at 600 volts.
Maximum Running Speed:
2,000 feet/minute (609.6 meters/minute)
OPTIONS:
- Heater wire systems (500 amp only)
- Stainless steel hardware
- Green bonding (ground) conductor covers, black "UV resistant" outdoor covers, and high-heat covers
- Curved systems - Contact the Factory
DURA-COAT - For Corrosive Environments
Hevi-Bar II is available with our optional DURA-COAT finish. Dura-Coat is a specially formulated coating that combines a ceramic compound with an epoxy binder to provide superior corrosion resistance and adhesion to the base materials. The entire bar is coated except in the stainless steel collector shoe running area; the insulating cover is applied over the coating.
All metal parts of the collector arm are coated. Arms are not coated as they are made from high-strength glass filled polymer.
DURA-COAT is an ideal conductor bar for galvanizing and electro-plating lines, chemical plants, smelters, foundries and cast houses, coke and ore handling cranes, and oxidizing/electro-winning facilities.
Downloads
![Motor Driven Reels Compact [C] Series](https://www.conductix.us/sites/default/files/styles/fancybox/public/compact_motor_driven_reels_neu.jpg?itok=h242Zwcy "Motor Driven Reels - Motor Driven Reels Compact [C] Series")
Motor Driven Reels
Compact [C] Series
Additional information
Optimal corrosion protection even in tough environments. Flanges and reel drum are manufactured from hot dip galvanized steel.
Reliable operation with standardized slip ring assembly.
Highly durable, maintenance-free and contactless torque transmission - standard motor with magnetic coupler.
Typical applications:
- Gantry cranes
- Overhead cranes
- Grabs or magnets
- Transfer cars
- Waste water treatment facilities
- Theater stage rigging
Product data
Specifications
Travel speed: up to 100 m/min
Winding length: 200 m max
OD of spool:
- Random wind spool: 400 mm - 1,700 mm
- Monospiral spool or 3-2-3 spool: 1,100 mm - 3,600 mm
Gearbox:
- Type W: 100 Nm - 400 Nm
- Type BNA: 300 Nm - 700 Nm
Slip ring assembly:
- Power max: 690 V – 200 A
- Control & Data max: 500V / 690 V - mA – 25 A
Temperature range: -20 °C - +60 °C
