The fiber-based Electric Monorail Systems – A Key to Competitive Production in the Future
Industrial production is undergoing a profound transformation. Rising energy prices, increasing cost pressures, shorter product life cycles, and international competition are forcing companies to continuously improve the efficiency of their production systems. At the same time, demand for flexible and high-performance manufacturing systems is on the rise, particularly in the automotive industry.
Against this backdrop, lightweight construction is becoming increasingly important. Modern lightweight construction concepts not only enable significant weight savings but also improve the energy efficiency, production speed, and cost-effectiveness of systems. A particularly illustrative example of this is the lightweight electric overhead conveyor (EHB) system developed by FFT.
This report explains how the system works from a technical standpoint, its advantages over conventional steel structures, and the importance of lightweight construction as a strategic success factor for the industry of tomorrow.
The fiber-based Electric Monorail Systems in Production
Electric overhead conveyor systems are among the most important conveying systems in modern production facilities. They automatically transport parts, vehicle components, even complete vehicles, and large goods between different production areas, thereby forming the backbone of many production processes.
Traditionally, these systems are primarily made of steel. Although steel is very strong, it is also quite heavy. This weight places a strain on both the conveyor system and the building structure and limits the system’s payload capacity.
FFT therefore takes an innovative approach and relies on modern lightweight materials, particularly carbon-fiber-reinforced plastics (CFRP). Thanks to our FFTlightweight Integral and FFTlightweight FibreTEC, we were able to reduce the weight by 70%.
In addition, the dynamic performance of the systems improves significantly:
Greater stiffness
The high specific stiffness of carbon fibers reduces deflection. The structure retains its shape even under high loads.
Shorter decay times
After acceleration or braking maneuvers, the composite fully utilizes its vibration-damping properties and significantly stabilizes the structure. This allows for shorter—and thus more intense—braking and acceleration ramps, which in turn enables shorter cycle times.
Lower inertia
The reduced weight decreases the moving masses. Drives and robots require less energy and can operate faster. This increases productivity while also reducing component wear.
These advantages are particularly evident in the fiber-based Electric Monorail Systems.
A conventional steel structure has a structural weight of approximately 2.38 metric tons. By using FFT lightweight construction technology, this weight is reduced to just 0.7 metric tons. This corresponds to a weight reduction of about 70 percent.
While in a conventional structure a large portion of the load-bearing capacity is already consumed by the structure’s own weight, the lightweight version offers significantly more payload capacity.
The weight savings of approximately 1.7 metric tons, combined with the load-bearing capacity of the existing steel beam, allow for a total load capacity of up to 2.9 metric tons. This makes it possible to transport larger and heavier components without requiring additional investment in the building structure.
Depending on the design, weight savings of:
• up to 40% compared to aluminum
• up to 57% compared to steel
• and, with an optimized design, even up to 70%
can be achieved.
Impact on Production Facilities and Infrastructure
This cost savings has a direct impact on the system's performance.
The importance of lightweight construction becomes even clearer when considering entire production facilities.
Suppose a factory has 200 fiber-based Electric Monorail Systems.
This results in:
• Steel construction: 480 metric tons total weight
• Lightweight construction: 140 metric tons total weight
The difference is an impressive 340 metric tons.
This enormous weight reduction offers numerous advantages:
• Less stress on the building structure
• Ability to use existing buildings without reinforcement
• Avoiding costly new construction
• Reduced foundation and steel construction costs
• Greater flexibility for renovations and expansions
This represents a decisive economic advantage, especially in times of rising investment costs.
Lightweight Construction as a Strategic Competitive Advantage
International competition is becoming increasingly fierce. Manufacturers in Europe are under pressure to produce cost-effectively, sustainably, and at the cutting edge of technology—all at the same time.
In this context, lightweight construction is emerging as a key factor for success.
The benefits go far beyond mere weight savings:
Energy Efficiency
Less mass in motion means lower energy consumption. This reduces operating costs and CO₂ emissions.
Higher Productivity
Lighter equipment can accelerate and decelerate more quickly. This reduces cycle times and thus increases production output.
Sustainability
Reduced material usage, lower energy consumption, and the ability to continue using existing infrastructure significantly improve the environmental footprint.
Faster Time to Market
More efficient production systems enable shorter production times and faster availability of new vehicles and products.
Cost Advantages
Lower production costs boost competitiveness and create room for more attractive product prices.
Especially in the face of global competition from manufacturers in Asia and North America, such efficiency gains can make all the difference. Companies that consistently rely on innovative lightweight construction solutions gain long-term competitive advantages and secure their market position.
