Modification and Expansion of a Pick-by-Light System
Expand or retrofit your pick-by-light system?
No problem. We’ll explain exactly how to do it and what you need to keep in mind.
Retrofit of a Pick-by-Light system
Upgrading a pick-by-light system must be as simple and straightforward as possible. Just like the picking process itself. New requirements, new concepts, and optimizations demand a high degree of flexibility from a pick-by-light system. For our system: No problem.
The basic concept behind the Pick-by-Light solution is to be as flexible as possible. This is the only way to create various customized solutions.
Rewiring
One of the most important aspects of flexibility is the freedom to configure the cabling of the pick-by-light system. Previous solutions always required a rigid cabling structure. Shift registers with terminating resistors were built, which could only be configured as a single strand.
Our cabling is topology-independent and can be configured as a bus or star network. Of course, a mixed configuration is also possible. You can learn more about the cabling and accessories in a separate article.
With the flexible technology used, the cabling can be easily adapted by adding an extension or a parallel expansion.
The only requirement that must be strictly adhered to is the maximum power rating of the controllers and, in the case of long cables, the total capacity, which must be calculated in that scenario.
Addition of new controllers
If the performance and capacity of the existing controllers are insufficient, new controllers must be installed. In this case, only the electrical parameters are relevant. The controllers do not perform any logical functions within the system and are used solely for communication with the pick-by-light bin indicators and the control computer.
Expanding the controller requires only a 230-volt power supply and a network connection. In some layouts, the controllers can form their own network, eliminating the need for additional network outlets. This naturally saves on the costs of retrofitting or expansion.
Software customization
Depending on the scope of the retrofit, the software for the pick-by-light system may also need to be modified. Our software offers a wide range of configuration options. If the workflow processes remain the same, no new software development is required. In this case, simply adjusting the configuration is sufficient.
Expansions of the Pick-by-Light system
Expanding the Pick-by-Light system follows the same rules as retrofitting it, so it is very easy to implement. The largest systems installed in recent years include up to 70,000 Pick-by-Light display units. The system has not yet reached its limits and can be expanded further as needed.
Conclusion
Modifying or expanding our pick-by-light system is relatively straightforward. The new pick-by-light bin indicators are connected to existing or new controllers and configured within the system. The software is updated as needed. To date, the system has not reached its capacity limits. We have sufficient capacity to build even larger systems.