The rail-based conveyor system for assembly and test automation
Self-propelled workpiece carriers on a passive conveyor line — safe, short takt times, maximum availability. 50 to 2,000 kg payload, ±0.6 mm positioning accuracy, 24/7 without charging interruptions.
* Measured in internal tests compared to conventional conveyor technology in continuous operation.
What is the LOGO!MAT eCart?
Unlike automated guided vehicles, the LOGO!MAT eCart follows a defined conveyor track. Self-propelled workpiece carriers with decentralized drives travel on a passive, maintenance-free rail and are continuously powered via an integrated 48V DC busbar. No batteries, no charging cycles, no traffic control required. Wiring and electrical hardware are already integrated into the system — interfaces to stations and higher-level systems are clearly defined.
The system is designed for structured assembly lines where deterministic takt times, maximum positioning accuracy and 24/7 availability are non-negotiable — particularly in e-mobility, automotive assembly and test automation. Dynamic travel profiles enable maximum scalability: from simple linear conveyor tracks to complex multi-line layouts. As an Industry 4.0-capable system, each carrier communicates bidirectionally with the higher-level PLC and enables complete process transparency along the entire line.
Safety is an integral part of the system: the two-channel braking system is TÜV-certified to ISO 13849-1 Performance Level D and allows collaborative operation with direct operator contact — without safety fences, without laser scanners.
Application areas
The LOGO!MAT eCart system is designed for the requirements of structured, highly integrated and cost-conscious assembly lines — in industries where takt time, payload capacity and process reliability are critical.
E-mobility & battery assembly
Industry standard for the assembly of battery modules and packs up to 2,000 kg — at leading OEMs and Tier 1 suppliers.
Automotive powertrain & axle assembly
Axles, gearboxes and drivetrains place the highest demands on payload capacity and positioning accuracy. The eCart transports heavy drivetrain components precisely and on takt through every assembly station.
Test & end-of-line automation
The integrated 48V busbar powers test equipment directly on the carrier — EOL tests and functional checks can partly be carried out takt-time-neutral during travel or at the station, without a separate power supply.
Mechanical engineering & heavy assembly
Heavy assemblies up to 2,000 kg, collaborative operation without safety fences, fully accessible conveyor track — the eCart system can be adapted to the requirements of complex special-purpose machines and assembly systems.
Four variants — one platform
All eCart variants share the same modular architecture with maximum commonality of hardware and components. eCart 700 and 700+ share the same 700 mm conveyor track and can be combined; the eCart 600 runs on a narrower 600 mm rail. Select based on your payload requirement.
eCart 600
- Payload: 50–600 kg
- Base footprint: 900 × 600 mm
Ideal for: electronics, gearboxes and standard assembly processes up to 600 kg
eCart 700
- Payload: 50–1,350 kg
- Base footprint: 1,000 × 700 mm
Ideal for: automotive powertrain, EV battery modules and universal heavy-duty assembly
eCart 700+
- Payload: up to 1,500 kg
- Base footprint: 1,000 × 700 mm
Ideal for: automotive powertrain components, heavy battery modules and axle assemblies up to 1,500 kg
eCart 700 Heavy
- Payload: up to 2,000 kg
- Base footprint: 1,000 × 700 mm
Ideal for: EV battery packs (full packs), heavy commercial vehicle axles and frames, large motors, hydraulic units and press tools up to 2,000 kg
What makes the system stand out
Every advantage is based on measurable values — no marketing language.
1 Fully accessible — no pits, no barriers
The conveyor track has a minimum installation height of 220 mm and is fully accessible. Operators can cross the line at any time — no safety fences, no light curtains, no lost production area. The system places no special requirements on floor condition. Existing hall floors can be used unchanged — no costly floor preparation required.
2 Zero Force Accumulation
eCarts accumulate with a variably adjustable gap and without mechanical contact between carriers. No accumulation pressure — even with a large number of eCarts, each carrier always stops smoothly and gently. Critical for sensitive assemblies such as battery modules or electronic components. Zero accumulation pressure means no uncontrolled rear-end contact — an inherent safety feature that requires no additional monitoring or sensors.
3 Performance Level D — certified for collaborative operation
The two-channel braking system of the eCarts and the Track Rotate modules is TÜV-certified to ISO 13849-1 Performance Level D. Speed is safely limited to a braking distance shorter than the bumper travel. When an obstacle detection bumper is triggered, the eCart stops in a controlled manner — even at 2,000 kg payload. Operation with direct operator contact without additional protective measures is permitted.
4 24/7 without charging interruptions
The integrated 48V DC busbar powers every eCart continuously — no batteries, no charging cycles, no fleet downtime. The busbar is maintenance-free and extremely long-lived. No battery replacement, no charging infrastructure, no battery-related downtime planning — this significantly reduces total cost of ownership over the entire system lifetime.
5 Self-diagnosis prevents downtime
Every eCart continuously monitors itself. Emerging issues are detected and transmitted to the main controller before a standstill occurs. Affected eCarts can be automatically routed to divert tracks based on these signals — the rest of the line continues running at full throughput.
6 Easy to expand and reconfigure
The modular rail construction enables expansions and layout changes without rebuilding the entire system. Individual track segments are added, relocated or reconfigured — the system grows with your production. Thanks to the decentralized control architecture, modifications are fast to implement not only mechanically but also electrically — often achievable during breaks, maintenance shifts or weekends.
PLC compatibility & interfaces
The LOGO!MAT eCart system is integrated directly into the network of a line controller or an existing plant network.
When is the eCart not the right choice?
The LOGO!MAT eCart is optimized for structured, high-efficiency assembly lines.
| Requirement | Why not eCart | Instead consider |
|---|---|---|
| Logistics transport between halls / buildings | eCart requires a fixed conveyor track | → AGV / FTS |
| Mixed operation on existing traffic routes | Dedicated rail infrastructure required | → AGV / FTS |
| Long takt times, only 2–3 vehicles | Rail infrastructure not cost-effective | → AGV / FTS |
| Heavy contamination / oil exposure | Sensitive drive technology | → Roller conveyors |
| Many carriers, low weight, low speed | System oversized for this requirement | → Roller conveyors |
Technical specifications
Variant-specific data
| Specification | eCart 600 | eCart 700 | eCart 700+ | eCart 700 Heavy |
|---|---|---|---|---|
| Payload | 50–600 kg | 50–1,350 kg | up to 1,500 kg | up to 2,000 kg |
| Base footprint | 900 × 600 mm | 1,000 × 700 mm | 1,000 × 700 mm | 1,000 × 700 mm |
System-wide data (all variants)
| Specification | Value |
|---|---|
| Travel speed (range) | 2–24 m/min** |
| Positioning accuracy | ±0.6 mm |
| Conveyor track installation height | min. 220 mm, fully accessible |
| Operating voltage | 48V DC, integrated busbar |
| Availability | >99.5% |
| Safety level | Performance Level D (ISO 13849-1) |
| Energy savings | >80%* vs. conventional technology |
* Measured in internal tests compared to conventional conveyor technology in continuous operation.
** 24 m/min is the mechanical maximum with the standard drive. In operator areas, speed must be reduced to the maximum safe speed for the respective application.
System components
| No. | Component | Description |
|---|---|---|
| 01 | eCart | Electrically driven workpiece carrier, flexible length, intrinsically safe, Zero Force Accumulation, data storage |
| 02 | Hydraulic Scissor Lift Table | 300 mm stroke, up to 1,500 kg, electro-hydraulic, optionally encoder-controlled, intrinsically safe |
| 03 | Electric Spindle Lift Table | 300 mm stroke, up to 1,500 kg, encoder-controlled, height adjustment during travel possible, intrinsically safe |
| 04 | Conveyor Track | Passive, low-maintenance, fully accessible, integrated busbar and Stop Unit mounting |
| 05 | Stop Units | Non-contact Stop Unit, bus connection, data communication to eCarts |
| 06 | Locating Unit | Safe detection, mechanical locking of eCarts, electrically actuated, manual emergency release, ±0.6 mm in travel direction, retrofittable at any Stop Unit |
| 07 | Stop Gateway | Up to 12 Stop Units per bus node, IP67 |
| 08 | Power Supply | Decentralized 48V system supply, 400–480V customer feed, fanless, all connections plug-in |
| 09 | Track Rotate | Ethernet connection, fully wired, 90° and 360° versions, up to 6 flexible exit angles, web visualization |
| 10 | Lift Gate | Manual or automatic, single or double-sided |
| 11 | Shuttle | Ethernet connection, fully wired, up to 4 exits per side, incremental position adjustment, web visualization |
| 12 | Docking Frame | Mechanical locking without control system, independent of lifting device |
| 13 | Lift | Up to 4 m lift height, four safety brakes, project-specific |
Frequently asked questions
Is the LOGO!MAT eCart an automated guided vehicle (AGV)?
No. Unlike automated guided vehicles, the LOGO!MAT eCart follows a defined conveyor track — workpiece carriers do not move autonomously through the production hall. This is not a limitation but the core of the system: a fixed rail guidance guarantees deterministic takt times and ±0.6 mm positioning accuracy without the use of laser scanners — both of which are inherently unachievable with an AGV.
For which applications is the eCart not suitable?
The system is optimized for structured assembly lines with defined station sequences. It is not the right choice when the primary task is logistics transport between different hall areas or buildings, when existing traffic routes are to be shared, with very long takt times and only 2–3 vehicles, with high levels of contamination and heavy oil exposure, or when a large number of workpiece carriers are required at low weight and low speed.
Which PLC systems and fieldbus protocols are compatible?
The eCart system is compatible with common industrial control architectures and supports all Ethernet-based bus systems, particularly Profinet and EtherNet/IP. For project-specific integration questions, contact our engineering team.
How long does commissioning of a standard system take?
Installation and commissioning typically takes approximately half as long as a comparable conventional conveyor system — a direct result of the modular rail construction and decentralized control architecture. For project-specific scheduling, contact our project engineering team.
Can the system be expanded retroactively?
Yes. The modular rail construction allows expansions through additional track segments and carriers without fundamentally altering the existing system. Stop Units can be relocated or added along the line. The system is designed to grow and change with production.
What happens in the event of a power failure?
All eCarts are stopped safely and in a controlled manner in the event of a power failure. For detailed information on emergency operating behaviour, contact our engineering team.
How does TCO compare to an AGV system?
The direct comparison depends on the specific application — in structured assembly lines the eCart system typically performs significantly better: lower acquisition costs, no batteries and therefore no battery replacement or battery maintenance, no scanner maintenance, no floor remediation required, and modifications can often be carried out in-house without external contractors, during breaks, maintenance shifts or weekends.
What safety certifications does the system hold?
The LOGO!MAT eCart is TÜV-certified to ISO 13849-1 Performance Level D. The two-channel braking system enables collaborative operation with direct operator contact without additional protective measures such as fences or light curtains.
Downloads
| Title | Format |
|---|---|
| LOGO!MAT eCart Broschüre (Deutsch) | |
| LOGO!MAT eCart Brochure (English) | |
| LOGO!MAT eCart Brochure (Français) | |
| 3D base model eCart 600 | STEP (CAD) |
| 3D base model eCart 700 | STEP (CAD) |
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