How to make the installation of a Pick-to-Light system

In this article we will explain the individual steps of the Pick-to-Light installation. You will learn which components, tools, accessories and electrical material are required for the installation. We not only show you the installation itself, but also explain in detail the various options for installation on different shelves, tables and mobile picking carts.

Which components are required for the Pick-to-Light installation?

First, the Pick-to-Light displays and their types must be defined. There are two different system variants that must first be defined (height 25mm and 50mm). Both variants can be combined with each other.
In a separate article you will learn more about Pick-to-Light planning. Also have a look at the list of available Pick-to-Light hardware (displays).

For a Pick-to-Light installation you need the following components:

  1. Pick-to-Light Displays
  2. Aluminum bottom profiles
  3. BUS line for the subprofile
  4. Terminals for connecting the cables
  5. Cover profiles and side covers
  6. Pick-to-Light Controller

Depending on the design and function of the Pick-to-Light system, additional components such as barcode readers, RFID readers, scales, batteries, etc. may be required. In this article, we limit ourselves to the pure Pick-to-Light installation, without additional hardware.

The required installation material

Besides the described main components, we need the following installation material for the Pick-to-Light installation:

  1. Pop rivets or screws
  2. Cable (4-wire)
  3. Wire end ferrules
  4. Cable tie
  5. Cable grommets (eventually)
  6. Cable conduits or cable ducts (only if required)
  7. Auxiliary angles and aluminum profiles (only if required)

The necessary tool

To perform the Pick-to-Light installation, the following machines and tools are required:

  1. High speed aluminum saw with special blades for clean cut of aluminum profiles
  2. Drilling machine
  3. Cordless screwdriver
  4. Drill
  5. Pop riveter (best battery)
  6. Wire stripper
  7. Crimping Pliers
  8. Screwdriver (cross and flat various sizes)
  9. Cutter knife

Pick-to-Light Installation step by step

1. mechanical installation of the lower profiles

We start the installation by attaching the aluminum sub-profiles to the substructure. To do this, first cut the sub-profiles to the appropriate lengths. Next, suitable holes are drilled in the sub-profiles for the fastening screws or pop rivets. Depending on the type of substructure, the Pick-to-Light subprofiles can be mounted directly or with auxiliary brackets.

Tip: During mechanical installation, special attention must be paid to sharp edges and protruding screws or pop rivets. All sharp edges must be treated or secured appropriately to prevent possible injury.

The attachment of the Pick-to-Light bottom profiles to the structure is usually done with screws or pop rivets. In some cases (e.g. heavy duty shelving) drilling of holes is not allowed. For this purpose, we have developed another fastening option using strong magnets. You will learn more about it later below.

2. mounting the Pick-to-Light controller

Once the bottom profiles are mounted, the Pick-to-Light controllers can be attached. The controllers can be installed directly on the shelves, on columns or walls. Sometimes small special constructions made of aluminum profiles are required.

Tip: When installing the Pick-to-Light controllers, care must be taken to ensure the correct orientation for passive cooling. The controllers contain power supplies that must be cooled. Covering the controllers is not permitted.

3. cable routes between the controllers and the Pick-to-Light subprofiles

Depending on the installation location of the controllers, possible cable routes for the cable routing of the supply lines must be built. Installation pipes or cable ducts can be used for this purpose. The services should be laid separately from the power lines (separator).

4. installation of the BUS system

Next, the BUS system is installed in the installed sub-profiles.

... further steps in the near future.