LOGO!MAT eCart Brochure — Digital Version Download PDF
KRUPS Automation — LOGO!MAT eCart
Intelligent Transport System for the Assembly Line
The LOGO!MAT eCart is a state-of-the-art conveyor system with self-driven, smart carts guided on a passive track — designed for short cycle times, maximum process safety, and minimal maintenance in automotive and industrial assembly.
Weight Capacity 50 to 2,000 kg · Performance Level D (PL-d) · 48 V DC via power rail · Speed up to 0.4 m/s
eCart vs. AGV — Footprint Comparison
AGVs and rail-guided eCarts differ fundamentally in their space efficiency and operational safety.
AGV (Automated Guided Vehicle)
- Large floor area required for vehicle movement
- PLS scanner clearance zones consume additional space
- Turning radius demands wider aisles and open floor
- Other traffic crossing the production space causes AGVs to decelerate and stop, increasing cycle times
- Safe emergency stop not possible using Wi-Fi
- Complex commissioning and significant maintenance requirements
LOGO!MAT eCart (rail-guided)
- Minimal space requirement and turn radius
- No need for PLS Scanner
- Short stopping distances
- Quick takt times for any production volume
- Safe emergency stop capability for defined track zones
- Quick and easy commissioning; minimal maintenance requirements
System Comparison: eCart — AGV — Roller/Chain Conveyor
Technical feature overview in direct comparison of the three most common conveyor systems used in assembly automation.
| Category | LOGO!MAT eCart | AGV | Roller/Chain Conveyor |
|---|---|---|---|
| Guidance | Self-driven cart, passive track system | Autonomous vehicle, no track system | Passive pallet, driven track system |
| Communication | NFC at Stop Units in the track system | Wi-Fi throughout | Sensors and RFID readers mounted to conveyor frame |
| Energy Supply | 48 V DC via power rail in track | Batteries | Fixed wiring |
| Safety Technology | Integrated safety bumpers, distance sensors, emergency stop capability | PLS Scanner required, safe emergency stop not possible using Wi-Fi | Reduced speed, double Stop Units, laser scanners not possible |
| Speed | Up to 0.4 m/sec | Up to 0.3 m/sec | Up to 0.2 m/sec |
| Stop Position Adjustment | Can be positioned or moved anywhere in the track system; no external personnel required | External personnel required | Can be positioned or moved anywhere in the track system; no external personnel required |
| Multi-Level Capability | Possible with elevator | Possible with elevator if certain conditions are met | Possible with elevator |
| Material Supply | Directly on floor or via platform | Directly on floor | Directly on floor or via platform |
| Commissioning & Maintenance | Quick and easy commissioning; minimal maintenance requirements | Complex commissioning; significant required maintenance | Quick and easy commissioning; minimal maintenance requirements |
| Cycle Times | Short cycle times | Longer cycle times | Short cycle times |
System Advantages in Detail
The LOGO!MAT eCart combines process safety, energy efficiency, and flexibility — designed for continuous operation in demanding manufacturing environments.
1Safe Operation
- Performance Level D (PL-d) per EN ISO 13849
- Safety bumpers in each direction of travel
- Two-channel active braking system
- Active braking on power outage or emergency stop
- Externally triggered two-channel emergency stop signals stop all movement in a defined track area
- eCart drives only when 24 V control signal is present
2Limited Drive Torque
- Drive torque electronically limited to minimum necessary level
- Individually adjustable per eCart
- Low driving force allows you to stop an eCart by hand without activating an e-stop
- Precise, repeatable acceleration out of all stop positions
3Zero Force Accumulation
- Stop Units require no physical contact with the carts
- Unlimited number of carts can accumulate with no buildup of force and no wear
- Drive motor shuts off automatically when cart stops — no energy consumed in accumulation
- Adjustable laser distance sensor ensures preset stopping distance from the cart ahead
- Smooth acceleration and deceleration within desired parameters
4Data Communication
- Wireless local data communication at each Stop Unit
- Cart parameters and workpiece carrier information can be read and written automatically
- Data transferred between main PLC and customer tooling while line is running
- NFC communication directly in the track
5Adjustable Accumulation Distances
- Minimum stopping distance between two eCarts is adjustable
- eCarts automatically maintain this minimum distance when accumulating at a Stop Unit
- Software-configurable — no mechanical retooling required
6Manual Cart Removal
- Comprehensive self-diagnostics proactively detect required maintenance or upcoming faults
- Optional remote control can manually drive the eCarts
- Carts can be manually moved if power is lost or shut off
- Production can continue if a faulty cart is removed from the line
- Carts can be easily reintroduced to the line
7Minimal Maintenance Requirements
- No moving parts in straight track sections
- Power rail tucked safely beneath the conveyor frame, protected from dirt and debris
- Track system is nearly maintenance-free
- No battery charging or replacement required — continuous power via rail
- Service intervals >10,000 h
8Tip Protection
- Optional hold-down bars and support rollers for large, over-hanging parts
- Safe transport of workpieces with uneven centers of gravity
- Retrofittable to existing eCart systems
9Power for your Tooling
- 48 V / 10 A DC auxiliary energy available on each eCart
- Powers your tooling device while the cart is in operation
- Enables lift and rotation mechanisms directly on the carrier
10Energy Efficiency
- System only consumes energy when in motion — drive motor shuts off at stop positions
- Stop Units are completely electric with no need for pressurized air
- At least 80% energy savings compared to conventional conveyor systems
11Scissor Lift
- Integrated hydraulic lifting platform with maximum stroke of 300 mm
- Lifts parts up to 2,750 lbs (approx. 1,250 kg)
- Places parts onto external structure with indexing points for precise positioning or high torque operations
- Adjustable workpiece height while moving between stations for ergonomic optimization
Applications
The LOGO!MAT eCart is used worldwide in automotive and industrial assembly — wherever precise workpiece transport, short cycle times, and PL D safety are required.
Battery Pack Assembly
Engine Assembly
Transmission Assembly
Drive Systems & Axles
Commercial Vehicle Frames
White Goods (50–500 kg)
Safety Concept PL-d: The eCart System meets Performance Level D (PL-d) per EN ISO 13849 — the foundation for deployment in safety-critical assembly processes in the automotive industry. Safety bumpers in each direction of travel, a two-channel active braking system, and zone-based emergency stop enable operation without full protective enclosures.
eCart Variants and Standard Dimensions
The LOGO!MAT eCart is available in three standard variants — matched to weight capacity and workpiece size.
| Variant | Weight Capacity | Standard Dimensions |
|---|---|---|
| eCart 600 | 50–600 kg | 900 × 600 mm |
| eCart 700 | 50–1,350 kg (optionally up to 2,000 kg) |
1,000 × 700 mm |
| eCart 900 | 50–1,350 kg (optionally up to 2,000 kg) |
1,200 × 900 mm |
Technical Features
- 4 wheels precisely guided along round steel shafts
- 48 V DC energy via power rail below the track
- Integrated 4.3" color HMI touchscreen for status, diagnostics, and parameter adjustments
- Safety bumpers mounted on each end; extended bumpers available for longer workpieces
- Custom tooling attachment points and Scissor Lift configurable
- Optional hold-down bars (Tip Protection)
System Components
The LOGO!MAT eCart system consists of matched components — from the passive track to the fully automatic elevator. All elements are modularly combinable.
Track
- Passive conveyor track with no moving parts — completely maintenance-free
- Integrated power rail (48 V DC) for carts and powered tooling
- Low profile version: only 220 mm tall, fully walkable
- Elevated version available with or without walkable center covers
- Mounting frame for Stop Units, Locate Units, and communication
Track Rotate Unit
- Replaces corners, intersections, diverters, and junctions
- Electrical drive motor for rotation and positioning
- Up to 4 attachment points for adjoining tracks
- Can be used as an idling spot for a cart
- Integrated Rotate Controller with web visualization
- Stop positions taught via web visualization; main PLC defines positions over BUS
Shuttle
- Moves entire track section laterally between up to four stationary tracks
- Lateral transfer or buffer function
- Can replace a 180° turn (cart travels backwards on parallel track)
- Integrated Shuttle Controller with web visualization
- Main PLC defines stop positions over BUS system
Lift Gate
- Section of track that can be raised to allow operators and material to enter a closed conveyor loop
- Available in manual or electric version
- Integrated Lift Gate Controller
- Customer controls give "open/closed" command over BUS system
Manual Docking Cart
- Easily removes or reintroduces an eCart to the line
- Locked to docking station at end of conveyor track
- eCart manually pushed onto cart and transferred to external operator or maintenance station
Elevator
- Transfers eCarts between levels of track
- Up to 3,300 lbs (approx. 1,500 kg) capacity
- Web visualization and dedicated controls integrated into main BUS
- Safety controls including sensors and gap controls
Stop Unit
- Fully electric, no physical contact with the cart
- Gentle, controlled stop
- Three communication antennae and a presence sensor
- Connected to main controls via Stop Unit Gateway
- Bidirectional communication between eCarts and main PLC
Locate Unit
- Electrically actuated mechanical pin indexes into eCart and locks it in place
- Positioning accuracy of ±0.6 mm in travel direction
- Mounted to base plate safely below the track rails
- Used with Stop Unit for high-precision operations
Scissor Lift
- Hydraulic lifting platform, maximum stroke 300 mm
- Up to 2,750 lbs (approx. 1,250 kg)
- Controls integrated into the eCart
- All signals exchanged via standardized Stop Unit interface
Virtual Commissioning
Virtual commissioning is far more than just a process simulation — eCart systems can be fully simulated, tested, and optimized before the first component is installed.
ISG Twinstore Integration
- Based on real controls interfaces displaying real-time behavior
- Digital versions of all eCart components available in ISG Twinstore
- Connect virtual model to real PLC to set up main controls and assembly line flow
- Commission your system before it hits the floor — mechanically installed and running in no time
Benefits of Virtual Commissioning
- Flow simulations and process optimization
- Rework planning and debugging without risk to real hardware
- Reduced on-site startup time and cost
- Show up to the customer's site with a runoff-ready system
Planning and Service from a Single Source
KRUPS Automation accompanies projects from initial planning through installation and beyond — with in-house manufacturing and on-site commissioning.
- LOGO!MAT Planning Tool for layout design and cycle time analysis
- Customer support starting in the project planning phase
- All system components manufactured in-house and tested before shipment
- Factory Acceptance Test (FAT) at our facility
- On-site installation, commissioning, and operator training
- Global service — headquarters Neuwied (DE), USA, China
KRUPS Automation GmbH · Auf dem Steinchen 4 · 56567 Neuwied · Germany · www.krups-automation.com