How to install a pick-by-light system
In this article, we explain the individual steps involved in installing a pick-by-light system. You will learn which components, tools, accessories, and electrical equipment are required for installation. We not only show you the installation process itself, but also explain in detail the various installation options for different shelves, tables, and mobile picking trolleys.
What components are required for the pick-by-light installation?
First, the pick-by-light displays and their types must be defined. There are two different system variants that must first be defined (height 25 mm and 50 mm). Both variants can be combined with each other.
You can find out more about pick-by-light planning in a separate article. Take a look at the list of available pick-by-light hardware (displays) too.
You will need the following components for a pick-by-light installation:
- Pick-by-Light displays
- Aluminum sub-profiles
- BUS line for the subprofile
- Terminals for connecting the cables
- Cover profiles and side covers
- Pick-by-Light Controller
Depending on the design and function of the pick-by-light system, additional components such as barcode readers, RFID readers, scales, batteries, etc. may be required. In this article, we will limit ourselves to the pure pick-by-light installation without additional hardware.
The required installation materials
In addition to the main components described, we require the following installation materials for the pick-by-light installation:
- Pop rivets or screws
- Cable (4-wire)
- wire end ferrules
- cable ties
- Cable glands (if necessary)
- Cable conduits or cable ducts (only if required)
- Auxiliary angles and aluminum profiles (only if required)
The necessary tools
The following machines and tools are required to carry out the pick-by-light installation:
- High-speed aluminum saw with special blades for clean cutting of aluminum profiles
- drill
- cordless screwdriver
- drill
- Pop rivet pliers (preferably cordless)
- wire stripper
- crimping tool
- Screwdrivers (Phillips and flathead, various sizes)
- cutter knife
Pick-by-Light installation step by step
1. Mechanical installation of the sub-profiles
We begin the installation by attaching the aluminum sub-profiles to the substructure. To do this, the sub-profiles are first cut to the appropriate lengths. Next, holes are drilled into the sub-profiles for the fastening screws or pop rivets. Depending on the type of substructure, the Pick-by-Light sub-profiles can be mounted directly or with auxiliary brackets.
Tip: During mechanical installation, particular attention must be paid to sharp edges and protruding screws or pop rivets. All sharp edges must be treated or secured accordingly to prevent possible injuries.
The Pick-by-Light sub-profiles are usually attached to the structure using screws or pop rivets. In some cases (e.g., heavy-duty racks), drilling holes is not permitted. For this purpose, we have developed an alternative fastening option using strong magnets. You can find out more about this below.
2. Mounting the pick-by-light controllers
Once the sub-profiles are installed, the pick-by-light controllers can be attached. The controllers can be installed directly on the shelves, on columns, or on walls. Sometimes small custom constructions made of aluminum profiles are required.
Tip: When installing the pick-by-light controllers, ensure that they are correctly aligned for passive cooling. The controllers contain power supplies that need to be cooled. Covering the controllers is not permitted.
3. Cable routes between the controllers and the pick-by-light sub-profiles
Depending on where the controllers are installed, cable trays may need to be installed to route the supply cables. Installation pipes or cable ducts can be used for this purpose. The power cables should be laid separately from the high-voltage cables (separating bar).
4. Installation of the BUS system
Next, the BUS system is installed in the sub-profiles that have been installed.
... further steps in brief.
