Integrated Power and Data for Automated Process Cranes

Keeping Container Logistics Moving

Recovering valuable metals from waste incineration residues requires more than sophisticated separation technology. Efficient material handling is equally important to keep the recycling process supplied and moving.

At the ZAV Recycling AG facility in Hinwil, Switzerland, dry bottom ash is processed to recover valuable metals for reuse. The facility's 130-meter-long container storage area accommodates specialized containers stacked up to four levels high. Two automated process cranes, by the Brun Marti Dytan AG, handle containers weighing up to 28 metric tons, moving them within the storage area to support the flow of material through the facility.

Coordinating these movements requires more than mechanical precision. Both overhead cranes need a continuous supply of electrical power and reliable data communication with the warehouse control system.

Integrated Power and Data Transmission

To meet these requirements, Conductix-Wampfler supplied an integrated solution combining the 0813 series SinglePowerLine conductor rail system with ProfiDAT^® data transmission technology. Together, the systems provide the power supply, data communication, and protective grounding infrastructure required for automated crane operation along the 130-meter travel route.

SinglePowerLine 0813: Reliable Power for High-Current Applications

The SinglePowerLine 0813 is a single-pole conductor rail system designed for demanding applications that require reliable power transmission to moving equipment. Its insulated design and high current-carrying capacity make it suitable for industrial crane installations.

At Hinwil, the system uses 800 A copper conductor rails and operates at 400 V. Each crane draws 331 A, resulting in a combined current of 662 A for the two cranes.

The conductor rail system provides a continuous power supply along the crane route, supporting the electrical demands of both process cranes as they move through the container storage area.

ProfiDAT^®: Shielded Data Communication for Automated Cranes

Automated container handling depends on reliable communication between the moving cranes and the warehouse control system. ProfiDAT^® uses slotted-waveguide technology to transmit data contactlessly between stationary and moving equipment.

Unlike conventional WLAN communication through open space, ProfiDAT^® guides radio waves within a specially designed waveguide profile. This integrated shielding helps contain the radio signal within the system, minimizing interference from other wireless networks or steel structures and reducing the exposure of data transmission to the surrounding radio environment. This makes ProfiDAT^® particularly suitable for demanding industrial applications where reliable, controlled communication is essential.

In this installation, ProfiDAT^® works with the Profinet protocol to provide the communication interface between the crane systems and the warehouse control system.

Another feature of the solution is the integration of protective grounding (PE) into the ProfiDAT^® profile. This combines data transmission and the protective earth function within the same system, helping to create a coordinated and space-efficient installation.

The Technology Behind Fully Automated Operation

The interaction between power supply, data communication, and crane control is central to the application. SinglePowerLine 0813 supplies the electrical energy, while ProfiDAT^® enables the data exchange required to integrate the cranes into the warehouse control system.

Together, the two technologies provide the infrastructure for fully automated crane operation across the 130-meter storage area. The solution supports the coordinated handling and stacking of heavy containers within a demanding industrial environment.

Supporting the Material Flow Behind Recycling

The container storage area plays a critical role in the overall recycling process. It serves as the interface between external logistics and the facility’s internal material flow, connecting incoming material deliveries with the downstream recycling operations. The two process cranes are essential to keeping this interface running efficiently, handling containers and coordinating material movements within the storage area. Reliable power transmission and shielded data communication provide the technical foundation for this automated operation, helping maintain the flow of materials through a key point in the process chain.

By combining SinglePowerLine 0813 and ProfiDAT^®, Conductix-Wampfler delivers an integrated solution for energy transmission, data communication, and protective grounding – tailored to the requirements of two automated process cranes in an industrial recycling facility.