Pallet rack
Conveying and Handling Technology

Pallet rack

Mobile pallet racking can fail without warning if wear goes unnoticed. With IoT, the racks continuously report operating hours, error codes and wear indicators to service.

Pallet rack at a glance

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  • Dexion GmbH

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Mobile pallet racking with IoT: preventing downtime

In the solution example, the Cumulocity IoT platform links the racks' sensors and controllers with the manufacturer's business systems. It records operating hours, error codes, energy figures and wear indicators. Telemetry is normalised and visualised in real-time dashboards. Rules and event logic automatically raise tickets or alarms, for example when electronic faults recur. The platform is integrated with the Mobile Field Report planning software, which handles tickets, service planning and maintenance scheduling. Multi-tenancy and role-based access keep customer environments separate.

The example comes from mechanical and plant engineering, with early damage detection and utilisation tracking as use cases. Storage technology manufacturer Dexion connects its MOVO mobile racking system with Cumulocity. Dexion previously relied on regular maintenance with checklists, but problems arising between service visits remained invisible. Now potential failures can be spotted earlier, remote diagnostics save on-site troubleshooting, and technicians set off with the right spare parts. Complete histories and threshold alarms help customers demonstrate safety and compliance. Usage data feeds into design, software and firmware.

Mobile pallet racking: frequently asked questions

How do remote diagnostics work for mobile pallet racking?

The racks send error codes, operating hours and wear indicators to an IoT platform, and service evaluates them remotely. At Dexion, Cumulocity does this for the MOVO mobile racking system. Traditional service calls often required troubleshooting on site. Now the right spare parts and technicians are determined before setting off, and service calls can be planned more precisely.

Does IoT monitoring replace pallet racking inspection?

No, it complements it. Dexion keeps regular maintenance with structured checklists and uses continuous monitoring to close the gap between service visits. For evidence, the connected MOVO racks provide event and condition logs, threshold alarms and a traceable history. This matters especially in safety-critical environments where customers have to demonstrate safety and compliance.

Which service models does connected pallet racking enable?

Predictable maintenance and, in future, performance- and usage-based service packages. Dexion uses the operating data from its MOVO system to move from being a storage systems supplier to a provider of data-based services. Higher availability and faster support strengthen customer loyalty. Real usage and fault data also feed into improving product quality, design, software and firmware.

What data does a mobile racking system provide?

Operating hours, error codes, energy figures and wear indicators. For Dexion's MOVO system, Cumulocity collects these values from sensors and controllers, normalises them and displays them on real-time dashboards. Built-in rules automatically raise tickets or alarms when predefined conditions occur, such as recurring electronic faults. The tickets then flow into the Mobile Field Report planning software.

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