Manufacturing Automation – Polyurethane Metering
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Power | Free Monorail Production Conveyor

Job Centered Powered Conveyor Systems


Konal’s patented “Smart Track” powered monorail conveyor systems have changed the way the world manufactures or processes polyurethane and automotive assemblies throughout the world. Smart Track is a unique manufacturing concept that follows the idea of Job-Centered Manufacturing. In doing this, Konal has been successful in producing manufacturing systems that often have running efficiencies boasting percentages in the mid nineties. Up-time numbers on systems that date back nearly a decade ago are still among the highest in the industry, producing up-time reports also greater than ninety percent.


Why Overhead Monorail Conveyors


Konal’s Smart Track systems combined with their innovative engineering are the secrets leading to improved efficiency for medium to high volume production lines and assembly of parts.

Smart Track is the “job-centered” manufacturing system from Konal: By studying the production line process steps involved in manufacturing a completed part or assembly, Konal develops systems based on our Monorail “Smart Track” production line system to eliminate unnecessary steps, duplicated tools and capital expenses, excess floor space requirements and labor content, thereby increasing your efficiency and reducing your overall manufacturing costs. By using a Konal automated manufacturing Monorail system you can increase your facilities efficiency.

Check It Out: Pictures of a Konal Powered Monorail Overhead System
What Does a Powered Overhead Monorail System Look Like?

Above ground, overhead monorail production line systems provide “clean floor” manufacturing. It means the ability to walk into the system without walking over “tracks or rails”, to be able to examine or service the system from the inside, often without stopping the manufacturing functions of the line.


Flexible Manufacturing


Overhead Monorail production line systems are flexible in design and layout. They can be placed near, or even around, existing structural supports instead of the typical situation wherein they must be fit into existing manufacturing bays or areas.

Konal Smart Track Monorail production line systems can be designed for invisible tool change or for repair off-line without stopping or even slowing down the production line!

Nearly all Smart Track systems process two or more materials in-line to manufacture a finished or nearly finished assembly or product. Multiple processes may be performed on each Smart Track line.

Smart Track mold carriers and assembly carriers are individually controlled by the Master Control System – they communicate with the control system by sending digital information that constantly updates the current status of the process. These carriers are then controlled by the Master Control System and are “instructed” to proceed to the next station or process or they are given alternate instructions.


Powered and Free Systems Work in Every Industry


Powered Racetrack Conveyor SystemSmart Track systems are used in the manufacture of numerous automotive interior components such as door panels, instrument panels, sound insulating products, skin manufacturing, foamed parts, structural rim parts and assemblies such as instrument panels, head rests and arm rests. Smart Track conveyor lines are used outside the automotive sector in the manufacture of medical equipment, consumer goods, recreational vehicle parts, lawn and garden equipment parts and much more.

Mold carriers for Smart Track conveyor lines are designed for the particular function in mind with multiple platen, tilting or rotating, and tonnages ranging from as low as 3 thousand pounds to 85 tons depending on the requirements. And weight is certainly not a problem for Smart Track. Many applications feature fast-moving mold carriers weighing as much as 20 tons.

Often, Konal engineers design systems where multiple manufacturing steps may be performed from both sides of the carrier at the same time, creating cells where robots and people can work together.

Smart Track mold carriers carry many patented features including a concept for achieving both tonnage and stripping force without the use of hydraulics. No hydraulics are used to generate tonnage on Smart Track carriers. Most of our customers ask for a “clean” manufacturing process without the possibility of hydraulic leaks on the finished part resulting in scrap or rework.

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.