How montratec uses a Visual Components‑based intralogistics configurator to improve planning reliability and efficiency

A company‑specific component library with integrated simulation enables faster quotations, validated layouts, and smoother implementation

Digital planning meets real‑world efficiency: montratec GmbH leverages an innovative combination of modular conveyor technology and intelligent software to design complex intralogistics processes with maximum flexibility and precision. Together with DUALIS, the company developed a company-specific configurator with an integrated simulation function based on Visual Components. This intralogistics configurator transforms the planning process, accelerates implementation, and elevates customer communication to a new level.

The most important facts at a glance

Initial situation / motivation

• High system complexity: Modular, multi‑track intralogistics solutions (switches, curves, lifts) made system design and planning challenging.
• Previous solution lacked simulation: A static Visual Components configurator and Excel‑based calculations offered limited transparency regarding cycle times, bottlenecks, and material flow.
• Risk of over‑/under‑dimensioning: Manual calculations were error‑prone, increasing the risk of overly conservative or insufficient planning.
• Challenging communication: Limited visual validation for sales and engineering.
• Objective: Implement a solution that supports design, communication, and project execution end‑to‑end.

Special features of the solution

• Joint development: Layout configurator with an integrated simulation function based on Visual Components
• Company‑specific component library mapping mechanics, control logic, and energy behavior in detail
• Validation tools & assistants: Automatic error detection; automated placement of control elements with presets
• Deep system logic: Realistic sensor behavior and shuttle dynamics; Python‑based extensions beyond standard Visual Components capabilities
• PLC & virtual commissioning: Reduced modeling effort via seamless switching between SPM and real PLC signal control
• Process and energy analysis: Simulation of material flow, bottlenecks, and optimal shuttle count; transparency on energy consumption and CO₂ footprint
• Integration: JSON export to SolidWorks; automatic BOM creation directly from the layout
• Reusability: Components available permanently in the Visual Components eCatalog
• OEM capability: Configurator also available to montratec customers and integrators

Benefits

• Faster, more accurate quotations using automatically generated BOMs
• Greater planning security thanks to realistic simulation of material flow, cycle times, and bottlenecks
• Shorter project lead times thanks to validation tools and early material procurement
• Reliable virtual commissioning via PLC connection and easy switching between SPM and PLC mode
• Sustainable system operation through energy/CO₂ transparency and optimized shuttle sizing
• Consistent quality with reusable standardized components

In the Video: Simulation of the montrac® modular monorail and shuttle transport system

Modular transport system from montratec – flexible, scalable, efficient

montratec GmbH, part of CMCO Conveyance Solutions, specializes in customized intralogistics solutions for assembly automation and production logistics. The focus lies on efficient processes and the seamless linking of individual production steps. With its modular monorail and shuttle transport system montrac®, montratec offers a scalable solution that adapts flexibly to various requirements, from manufacturing and assembly to warehouse logistics.

The system is based on a rail‑guided structure with autonomously moving shuttle vehicles, similar to a model railway. These shuttles can change direction using curves or switches and move between levels via lifts, enabling highly flexible track layouts.

All components – rails, switches, stations, and processing areas – are modular and customizable. This allows the implementation of simple as well as highly complex transport processes, from serial and parallel workflows to multi‑line systems.

A major advantage is the system’s scalability: it can be expanded to hundreds of shuttles and easily adapted to changing requirements, for example by replacing curves with switches to add new routes.

Challenge: making complexity manageable

montratec solutions are extremely modular and flexible which makes planning and system dimensioning equally complex. “Our product can take on very complex forms,” explains Matthias Magrian, Product Manager at montratec GmbH. “We wanted to map this complexity and give our employees the opportunity to simulate systems, identify problems at an early stage, and exploit optimization potential.”

Before working with DUALIS, montratec used a static Visual Components configurator without simulation and relied heavily on Excel‑based calculations. This approach provided limited transparency and made it difficult to visually evaluate planning decisions or assess process flows dynamically.

Manual calculation of shuttle counts, process times, and material flows was time‑consuming and error‑prone. Particularly for customer‑specific requirements, there was a significant risk of incorrect sizing – either too conservative or too generous – which directly affected costs, delivery capability, and customer satisfaction.

It became clear that a modern solution was needed – one that makes system complexity manageable and digitally supports planning, communication, and implementation across all departments.

The Solution: a flexible configurator with integrated simulation

In the search for a suitable partner, montratec turned to DUALIS. The Dresden‑based software company offers consulting, development, and system integration from a single source. Together, they developed a company-specific component library within Visual Components that digitally represents the entire montratec product portfolio.

The key innovation: This library acts as a configurator with an integrated simulation function. The components incorporate specific behaviors such as sensor logic, control functionality, and automated routines that exceed the standard capabilities of Visual Components. Users configure transport lines in a 3D environment, simulate material flows, and automatically place control components.

Implementation of the solution

Configuration, validation & assistance functions

An integrated validation tool automatically checks whether all components are correctly linked. Incorrect or incomplete connections are visually highlighted, enabling targeted corrections. Another assistant supports the automatic placement of control elements at decision points such as switches or curves, including predefined settings for speed, distance, and logic. This reduces manual effort and saves time.

The solution also incorporates electrical and pneumatic aspects. It calculates cable lengths and hose routing based on the layout and automatically places cable channels depending on system volume and structure, resulting in a continuous digital representation of the transport line.

Component configuration mirrors the later real‑world control system: motion sequences, dwell times, target definitions, and decision logic can be simulated realistically and transferred directly to commissioning. The shuttles themselves are highly configurable, including length, axle spacing, speed, and acceleration.

Simulation, PLC integration & energy efficiency

The programming implemented by DUALIS features exceptional detail and accuracy. Sensor logic and shuttle behavior are modeled so realistically that the solution significantly surpasses standard Visual Components functionality. Multiple custom Python extensions were developed – for example: A sensor does not detect a shuttle if it stops outside the tolerance window above the sensor. This may occur if speed markers are misaligned or if the shuttle enters too quickly and fails to brake correctly. The configurator detects such scenarios early and enables targeted corrective actions.

The control elements provide all the signals required for real communication with a PLC. Users can seamlessly switch between:

• internal behavior based on Visual Components Standard Process Modelling (SPM), and
• external control via a real PLC.

This reduces the modeling effort for virtual commissioning considerably.

An integrated process model enables simulation of complex workflows, including interactions with robots and additional conveyor technology. Users can analyze material flows, identify bottlenecks, and determine the optimal number of shuttles for maximum throughput.

Energy efficiency is also supported: only the shuttles consume power, making the system inherently energy‑efficient. The simulation captures energy consumption and evaluates it per subsystem and for the overall process, including CO₂ footprint calculations.

Seamless integration into existing system landscapes

The configurator is designed to avoid media breaks and data loss while integrating smoothly with existing tools. A key example is the jointly developed interface to SolidWorks, implemented together with an integration partner. The layout configuration, including placement and configuration of all elements, is exported in a text‑based JSON format. The partner solution reconstructs the layout in SolidWorks using existing CAD models, allowing engineering and planning to mesh seamlessly and reuse data efficiently.

Another central feature is the automatic generation of a detailed bill of materials (BOM) directly from the layout. It includes mechanical and electrical components, cabling, tubing, and exact lengths and positions. This accurate data can be transferred directly into the quotation process, speeding up proposal generation and improving planning reliability.

Advantages before order placement – from marketing to simulation

Even during early customer engagement, the solution based on Visual Components and the DUALIS library delivers numerous benefits:

• Marketing: High‑quality images, animations, and simulation videos can be used for brochures, websites, and social media – ideal for visually conveying complex systems.
• Trade fair planning: Concepts and solutions can be prepared in advance and presented clearly and convincingly.
• Sales: Customer‑specific applications can be presented in 2D, 3D, or VR – building trust and improving communication of technical details.
• Budgeting & quotations: Automatic BOM generation enables fast and accurate quotations, capturing dynamic components and reducing errors.
• Simulation: Simulation can be offered as an additional service to validate concepts, optimize process flows, and quantify customer benefits.

Advantages after order placement – from project management to installation

Once an order is placed, the solution supports project execution across all departments:

• Project management: Information exchange improves significantly – internally and externally.
• Order scope: Automated validation ensures completeness of all components. Standard parts are captured visually and data‑based.
• Engineering: Automated software functions reduce effort in mechanical and electrical design – lowering costs.
• Internal processing: Material procurement can begin earlier thanks to the complete BOM, shortening project duration.
• Service: Commissioning preparation becomes more efficient and precise.
• Installation: Reduced installation time and fewer missing components.

The system is based on standardized components, most of which were created by DUALIS. As they remain available in the Visual Components eCatalog, they can be reused for future projects, reducing effort, ensuring consistent quality, and speeding up project planning.

Future outlook: OEM configurator for customers and integrators

A major milestone was the decision to enter into an OEM partnership. montratec now offers customers and integrators their own configurator based on Visual Components. Users can design logistics systems using montratec modules and perform simulations as needed.

Conclusion: digital efficiency meets customer‑specific precision

The combination of the montrac® modular transport system, Visual Components, and the intelligent DUALIS component library creates a powerful platform that unites technical precision, visual communication, and digital efficiency. The solution enhances internal processes and strengthens customer trust. Transparent, understandable, and visually impressive concepts make the added value immediately clear.

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