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Mecalux’s floor-mounted Electric Monorail System (EMS) is one of the fastest solutions for uninterrupted goods transport within a warehouse or manufacturing centre.
Agile in-house material transport
A floor-mounted electric monorail system comprises automatic vehicles (carriers or trolleys) powered by electric motors that travel autonomously along an electrified rail embedded in the floor.
Each carrier is equipped with a hybrid roller and chain conveyor for handling different types of pallets, regardless of their orientation or format (European, GMA and others).
The trolleys used in a floor-mounted EMS can transport loads of up to 1,500 kg at high speed, reaching up to 2 m/s. This enables fast, continuous movement over long distances in warehouses and production facilities.
Each floor-mounted electric monorail carrier is preconfigured for seamless system integration, ensuring fast, hassle-free installation with no adjustments required
Continuous movement within a loop
Floor-mounted electric monorail systems operate in a closed-loop configuration and span medium to long lengths. Typically installed at the front of the warehouse, they connect storage zones with picking or dispatch areas. They can also link individual logistics centres, a warehouse with a manufacturing facility and even separate buildings via an enclosed elevated bridge.
The EMS loop includes multiple loading and unloading stations positioned along the route. It is divided into sections that operate independently and feature diverters, switches and alternate routes that allow the trolleys to take secondary paths. This prevents them from having to complete the entire loop to reach different stations. The segmented structure offers several advantages: it shortens travel times to loading and unloading points, reduces kilometres for each carrier, minimises component wear and ensures continuous system uptime — even in the event of a disruption.
Thanks to a barcode system embedded along the electrified rail, each carrier identifies its position in the loop with pinpoint accuracy
Software that controls autonomous movement
To perform reliably, a floor-mounted EMS requires control software that coordinates and synchronises trolley movements. Fully integrated with the warehouse management system (WMS), this solution organises goods flows based on companies’ logistics needs.
The control software plans and manages each carrier’s route using a set of rules and parameters designed to optimise system performance. It considers variables like load weight, task priority and line congestion to determine the shortest, most efficient path for each trip. The software also implements load-balancing strategies, distributing only the necessary number of trolleys to each zone. This avoids traffic build-up while ensuring a continuous, steady flow. As a result, productivity increases, travel times are shortened and equipment wear is kept to a minimum.
To maintain peak performance, the electric monorail system also includes preventive maintenance routines. After a trolley reaches a defined kilometre threshold, the control software automatically reroutes it to the maintenance area. There, technicians inspect components, replacing or repairing them as needed.
Warehouse operators can consult information on each trolley’s condition, such as motor usage and wheel wear levels
Advantages of floor-mounted electric monorail systems
- Autonomous, intelligent transport. The vehicles operate independently and communicate with each other to maintain a continuous, coordinated flow of goods.
- High operating speed. Floor-mounted electric monorails move goods quickly, making them ideal for covering long distances within or between buildings.
- Expandable, adaptable loop. The EMS is designed to match the facility’s layout, with the flexibility to incorporate curves and branches. It can be easily modified to add new stations, maintenance zones or accommodate future expansions.
- Efficient use of resources. Only the necessary carriers are activated, reducing energy consumption and extending component life.
- Real-time coordination and fleet balancing. The control software manages routes to prevent congestion, distribute vehicles evenly throughout the loop and keep operations running smoothly.
- Preventive maintenance. The system monitors wear on key components such as wheels and motors in real time, indicating the optimal time for inspection. Maintenance staff can check this information instantly from a tablet.
- Next-generation vehicles. The latest monorail trolleys have been redesigned to deliver top performance in speed, energy efficiency and durability.