The process workflow in a P2L assembly system usually looks as follows:
- Selection of an assembly flow from the program Management
- Manual picking by the Operator
- correct component picked: PLC broadcasts next picking step according to assembly recipe (continue at 2.)
- PLC broadcasts picking order to sensor of the next component’s container
- wrong component picked: consequence, such as signalling sounds, ejection of the component or other
- End of the assembly procedure (continue at 1.)
This film demonstrates a Pick-to-Light sensor at a stall. Shown are a simple working process, what happens when a worker reaches into a wrong container and the teaching function.
Characteristics and advantages
With P2L sensors, high process safety in assembly and picking operations can be accomplished. This represents a great economic advantage, especially in processes where a lot of variants and small batches are to be worked with.
The sensor is teachable and can be fit to different container shapes and filling levels. By receiving a signal sent by the PLC, the P2L sensor is optimised for the current set of containers, materials and filling heights. The teaching signal can be sent manually via button-press or integrated in the PLC start routine.
The small construction and the small minimal distance allow even racking levels, which ensure ergonomic deployment architecture with shorts handling ranges. A removal from a compartment does not have to be confirmed, as the P2L sensor recognizes this automatically.
For large assembly systems with many sensors, the use of P2L sensors with CAN bus is recommended because the wiring is less time-consuming: all P2L C002 are wired in series and only a supply line to PLC is required.
With the P2L C002 sensor, the LEDs over the CAN bus can be individually controlled, depending on the process requirements.