Expansions of the Pick-by-Light system
Barcode scanners, RFID readers, scales, and label printers are often connected to a pick-by-light system as add-ons. In this article, you’ll learn how to connect these devices to the system and what options and features are available.
Functions of the add-ons for a pick-by-light system
In certain complex processes within a pick-by-light system, additional devices are required. These devices are used in various ways and generally serve the following functions:
- Manual and automatic activation of orders
- Recording of serial numbers and batch numbers
- Weight checks during order picking
- Label creation
Paperless picking does not necessarily mean working entirely without paper. The picking process itself is actually paperless.
Activation of orders
Pick-by-Light can be used for many purposes. These include: order picking, sorting, assembly, packaging, etc. Orders are often activated by scanning a barcode or RFID tag. Delivery notes, invoices, product codes, or assembly instructions are ideal for this purpose. The barcode or RFID tag contains the order number, product code, production number, or delivery note number.
The scanners or RFID readers transmit the scanned data directly to the LUCA-Server, which is then responsible for activating the orders. The server processes the data and then controls the individual pick-by-light bin indicators.
Recording of serial numbers and lot numbers
Especially in order picking, the recording of serial numbers and the verification of batches are very common. Mobile handheld scanners are often used for this purpose.
In this case, the serial number of the devices or parts is recorded each time an item is removed from the storage bin and forwarded to the warehouse management system along with confirmation of the removal. The transmission of batch numbers—and even the comparison of specified batch numbers—is also carried out during picking using the pick-by-light system.
Weight Control in Order Picking
To ensure perfect quality control, the weight of the picked items can also be checked directly during the picking process. At the start of the picking process, the tare weight of the box or container is recorded first. With each item, the system checks the increase in the shipment’s weight. If the weight is correct, the next item can be picked.
However, this requires that the items have a consistent weight and that the master data is accurate. Checking weights directly during the picking process improves quality, but it has one drawback: it reduces picking efficiency. Learn more about this feature in a separate article on Pick-by-Weight.
Label printer
Small label printers can also be connected to a pick-by-light system. Depending on the workflow and how the system operates, it controls the direct printing of labels.
This can be used, for example, for labeling items or cardboard boxes. The order picker can also apply labels directly while manually folding the boxes.
Connecting the expansion units to the pick-by-light system
Depending on the type of device, we have various options for connecting to the pick-by-light system.
Connecting the wired handheld scanners
Wired scanners are very often LUCA-Server directly to the LUCA-Server via a workstation PC or a network. USB ports are frequently used on the PC. A direct connection of the wired scanners to the network is often achieved using ComServer. In this case, however, the RS232 interface is used.
USB and RS-232 devices can also be connected directly via the controllers of the pick-by-light system. Therefore, a PC or ComServer is not strictly necessary for this purpose.
Use of radio scanners
Wireless scanners are often used in stationary pick-by-light systems. These mobile devices give employees at their workstations greater freedom of movement and flexibility.
Modern wireless scanners have a direct Wi-Fi connection to the network. Some models come with charging stations equipped with LAN, USB, or RS232 ports, which, like wired scanners, are connected to the pick-by-light system (as described above).
RFID reader
Basic RFID readers are connected in a similar way to wired scanners. Instead of reading barcodes, RFID readers read information from RFID tags. Depending on the application and solution, they can read items, picking carts, or other identifiers.
The interesting thing about RFID is that the tags can also be programmed. This means that information is transmitted directly along with the tag. This application is particularly useful in manufacturing.
There are many models on the market that are suitable for this application. If you have any questions, please contact us. We’ll be happy to help.
Connecting the scales
These scales are often highly accurate and are used in a stationary setting. This makes connecting them via a PC, LAN, or ComServer the most practical solution.
Integration of label printers
Label printers are usually connected to the Pick-by-Light system via a Pick-by-Light controller, PC, or LAN. Mobile label printers (Wi-Fi) can be used without any issues. The LUCA-Server always controls the label printers.
Conclusion
The Pick-by-Light system can be expanded to include a variety of additional devices. Depending on the workflow and functionality, scanners, RFID readers, scales, and label printers can be connected. If needed, we can also develop interfaces for specialized devices if we do not already have them available. Please contact us for more information.