Manufacturing Automation – Polyurethane Metering
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Overhead MonoRail Conveyor

Smart Track Overhead MonoRail Conveyor


The Konal “ Smart Track” is an electrified overhead rail conveyor drive system for material handling. We have designed a unique tracking system that allows each individual carrier to operate as a separate entity. Each “Smart Car” is self propelled and its speed can vary depending on its position in the system. Variable speeds allow for quick movement between operations minimizing non productive positioning of your valuable tooling.

Overhead Monorail Power and Free Manufacturing LineThe goal of the Konal “Smart Track” System is to provide the RIM (Reaction Injection Molding) industry with equipment that reduces the amount of capital assets and tooling required in a material handling system. Increased labor effectiveness is another aim of the “Smart Track”. To achieve this goal, it is necessary to divide up the task proportionately so that all operators are working as close to 100% efficiency as possible. We also select highly capital intensive components, such as robots, metering units, etc., and make sure they are running at peak efficiency within our Smart Track Conveyor System.

To incorporate our system, projected production volumes must be known and control points must be established as close to 100% efficiency as possible. Control points by our definition are points in a system at which the slowest operation will occur. This becomes the focal point for the rest of our calculations. This is sometimes referred to as the bottleneck. After control points are established, we parallel operations that take longer than the control point time so that maximum efficiency is maintained. This allows us to determine non functioning tooling and equipment.

After production volumes, control points and efficiencies are determined, we can design a material handling system that best combines your equipment and labor resources allowing your company to achieve increased capacity, cost effectively.




Track sections are prefabricated with conductor bars attached. Three of the conductor bars supply 3 phase power to the carrier, others are utilized by our “Smart Track” for automatic segregation of carriers and sending discrete messages to the carriers.

The overhead rail track sections are manufactured from standard heavy duty “I” beam rail.

The Konal “Smart Track” is mounted on standard stand sections. These stands will hold the track at the desired height. They are designed to allow the system to be reconfigured into other shapes at a later time to facilitate product changes. The stands are made out of heavy structural steel tubing with telescoping legs to easily and quickly adjust the system height and level.




RIM presses are incorporated into each “Smart Track” Monorail system carrier. Each carrier will have 4 sets of trolleys. Two sets will be drive trolleys and the other 2 sets will be idler trolleys. These will help carry the load of the press and help to take sharp turns in the track. For each drive trolley the drive source will be an inline helical drive motor. Each drive trolley motor will have its own integral brake which is used for E-stop only. This system applies force to the bottom of the track via a urethane wheel. This force is controlled by a preloaded spring setting that gives consistent pressure. In the event that power is lost to a carrier, a release screw system allows this pressure to be released and the carrier pushed along manually.

The “Smart Cars” are controlled by our “Smart Track” unique tracking system. This system includes a frequency inverter, allowing for slowing, braking or speeding up as required. It also allows each carrier to sense when it is approaching another and slows it to a gradual stop. The “Smart Track” System alerts any following carriers to do the same as they close up. The Smart Cars are equipped with safety bumpers for emergency stopping. Controlled starts and stops can be initiated as required by the Master Control System.

Please contact us with any of your questions, we will arrange to have a salesman meet with you to discuss any of your questions or concerns and help to customize a system to the requirements needed for your product.