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How to Install Pick-to-Light Hardware

Updated

Pick-to-Light is a mobile cart-based picking assistance system designed to improve speed and accuracy for multi-item batch picking. LED light modules mounted directly onto a mobile picking cart visually guide pickers to the correct tote for each item scanned.

Before You Begin

  • Hardware kit: your kit includes the following items. 

    • 1 ShipHero Shield Hub
    • 1 QR code placard
    • 26 LED lights
    • 14" and 7" male-to-male connectors (plus extras)
    • Female-to-female connectors
    • 1 battery pack (shipped separately)
    • 1 battery case
    • 1 90° USB-C to USB-C cable
    • 1 standard USB-C to USB-C cable (extra)
    • 1 T15 torque wrench
    • Small zip ties
    • Gaffer tape
  • Other materials: A picking cart, totes, an iOS device (iPad or iPhone) with the latest ShipHero app installed, and a paired 2D Bluetooth scanner connected to the iOS device.

For an overview of what Pick-to-Light does and when to use it, see Overview: Pick-to-Light in ShipHero.

Table of Contents

Setup Part 1: Install the Shield Hub and Battery

  1. Adjust Clamps: Use the T15 torque wrench to adjust the clamps on the ShipHero Shield Hub so they fit securely onto your picking cart's frame.
  2. Attach Hub: Mount the Shield Hub near the top row of totes, typically on the right side of the cart. The port labeled output must be positioned closest to where the first tote in your sequence will be located.
  3. Mount Battery Case: Secure the battery case to the underside of the cart's top shelf.
  4. Insert Battery and Connect: Slide the battery pack into the case. Use the included 90° USB-C to USB-C cable to connect the battery to the Hub's power input. Route the cable neatly.
  5. Secure QR Code: Attach the QR code placard firmly to the cart frame using the provided zip ties, in an easily scannable location.

QR Code Is Paired to Its Hub

This QR code is permanently paired with its Hub. Do not separate the QR code from its matching Hub. They're linked together for identification.

Setup Part 2: Wire the Top Shelf

  1. Position Lights: Place one LED light bar in front of each tote location on the top shelf. The side of the LED bar labeled input must face toward the Shield Hub. Don't fully tighten the clamps yet.
  2. Connect Hub to First Light: Plug one end of a male-to-male connector into the Shield Hub's output port, and the other end into the input port of the first LED light bar in your sequence.
  3. Link Subsequent Lights: Daisy-chain the remaining LED bars on the shelf, connecting the output port of one bar to the input port of the next.
  4. Prepare for Next Shelf: Route the cable from the output port of the last LED bar on the top shelf down along the cart's post toward the first tote location of the shelf below.

Setup Part 3: Wire Subsequent Shelves

  1. Connect First Light: Use a longer male-to-male connector (extend with female-to-female connectors if necessary) to connect the output from the last light of the shelf above to the input of the first light on the current shelf.
  2. Link Remaining Lights: Use short male-to-male connectors to link the rest of the LED bars on this shelf, output to input.
  3. Alternate Clamp Orientation: Alternate the screw orientation on the LED bar for each shelf as lights transition to the next shelf, for example shelves 1, 3, and 5 face up while shelves 2 and 4 face down.
  4. Secure Cables: Use the provided gaffer tape to neatly secure the vertical cable runs along the cart posts between shelves. This prevents snagging and keeps the setup tidy.
  5. Repeat: Repeat this process for all shelves on the cart.

Setup Part 4: Finalize Physical Setup

  1. Tighten Clamps: Once all lights are connected and positioned correctly, go back and securely tighten all the LED light bar clamps using the T15 torque wrench.
  2. Cable Management: Double-check all connections. Use additional zip ties or gaffer tape as needed to keep wiring secure and out of the way.

Pair and Test Your Pick-to-Light Cart

  1. Power On: Make sure the battery pack is charged and connected to the Hub.
  2. Open ShipHero App: Launch the ShipHero mobile app on your paired iOS device.
  3. Navigate: Go to the Multi Item Batch Picking section.
  4. Pair Cart: Scan the QR code placard you attached to the cart. This links the physical cart setup to the app.
  5. Configure and Test: Go to Settings, then Pick-to-Light Settings, and set the exact number of totes your cart uses. Run the Test function to illuminate each light in sequence (or test lights individually) and confirm every connection works before you start picking.

Once paired and tested, pick as you normally would with Multi-Item Batch picking: the LED lights illuminate the destination tote as you scan each item, and turn off once the quantity is satisfied.

Troubleshooting Resources

If your Pick-to-Light cart isn't behaving as expected during setup, pairing, or a pick, see Troubleshooting a Pick-to-Light Station.

Pick-to-Light is a mobile cart-based picking assistance system designed to improve speed and accuracy for multi-item batch picking. LED light modules mounted directly onto a mobile picking cart visually guide pickers to the correct tote for each item scanned.

Before You Begin

  • Hardware kit: 1 ShipHero Shield Hub, 1 QR code placard, 26 LED lights, 14" and 7" male-to-male connectors (plus extras), female-to-female connectors, 1 battery pack (shipped separately), 1 battery case, 1 90° USB-C to USB-C cable, 1 standard USB-C to USB-C cable (extra), 1 T15 torque wrench, small zip ties, and gaffer tape.
  • Other materials: A picking cart, totes, an iOS device (iPad or iPhone) with the latest ShipHero app installed, and a paired 2D Bluetooth scanner connected to the iOS device.

For an overview of what Pick-to-Light does and when to use it, see Overview: Pick-to-Light in ShipHero.

Table of Contents

Setup Part 1: Install the Shield Hub and Battery

  1. Adjust Clamps: Use the T15 torque wrench to adjust the clamps on the ShipHero Shield Hub so they fit securely onto your picking cart's frame.
  2. Attach Hub: Mount the Shield Hub near the top row of totes, typically on the right side of the cart. The port labeled output must be positioned closest to where the first tote in your sequence will be located.
  3. Mount Battery Case: Secure the battery case to the underside of the cart's top shelf.
  4. Insert Battery and Connect: Slide the battery pack into the case. Use the included 90° USB-C to USB-C cable to connect the battery to the Hub's power input. Route the cable neatly.
  5. Secure QR Code: Attach the QR code placard firmly to the cart frame using the provided zip ties, in an easily scannable location.

QR Code Is Paired to Its Hub

This QR code is permanently paired with its Hub. Do not separate the QR code from its matching Hub. They're linked together for identification.

Setup Part 2: Wire the Top Shelf

  1. Position Lights: Place one LED light bar in front of each tote location on the top shelf. The side of the LED bar labeled input must face toward the Shield Hub. Don't fully tighten the clamps yet.
  2. Connect Hub to First Light: Plug one end of a male-to-male connector into the Shield Hub's output port, and the other end into the input port of the first LED light bar in your sequence.
  3. Link Subsequent Lights: Daisy-chain the remaining LED bars on the shelf, connecting the output port of one bar to the input port of the next.
  4. Prepare for Next Shelf: Route the cable from the output port of the last LED bar on the top shelf down along the cart's post toward the first tote location of the shelf below.

Setup Part 3: Wire Subsequent Shelves

  1. Connect First Light: Use a longer male-to-male connector (extend with female-to-female connectors if necessary) to connect the output from the last light of the shelf above to the input of the first light on the current shelf.
  2. Link Remaining Lights: Use short male-to-male connectors to link the rest of the LED bars on this shelf, output to input.
  3. Alternate Clamp Orientation: Alternate the screw orientation on the LED bar for each shelf as lights transition to the next shelf, for example shelves 1, 3, and 5 face up while shelves 2 and 4 face down.
  4. Secure Cables: Use the provided gaffer tape to neatly secure the vertical cable runs along the cart posts between shelves. This prevents snagging and keeps the setup tidy.
  5. Repeat: Repeat this process for all shelves on the cart.

Setup Part 4: Finalize Physical Setup

  1. Tighten Clamps: Once all lights are connected and positioned correctly, go back and securely tighten all the LED light bar clamps using the T15 torque wrench.
  2. Cable Management: Double-check all connections. Use additional zip ties or gaffer tape as needed to keep wiring secure and out of the way.

Pair and Test Your Pick-to-Light Cart

  1. Power On: Make sure the battery pack is charged and connected to the Hub.
  2. Open ShipHero App: Launch the ShipHero mobile app on your paired iOS device.
  3. Navigate: Go to the Multi Item Batch Picking section.
  4. Pair Cart: Scan the QR code placard you attached to the cart. This links the physical cart setup to the app.
  5. Configure and Test: Go to Settings, then Pick-to-Light Settings, and set the exact number of totes your cart uses. Run the Test function to illuminate each light in sequence (or test lights individually) and confirm every connection works before you start picking.

Once paired and tested, pick as you normally would with Multi-Item Batch picking: the LED lights illuminate the destination tote as you scan each item, and turn off once the quantity is satisfied.

Troubleshooting Resources

If your Pick-to-Light cart isn't behaving as expected during setup, pairing, or a pick, see Troubleshooting a Pick-to-Light Station.

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