Logistics Sorting Line
High-density wireless solutions delivering 50% greater throughput with sub-50ms latency for peak-season sorting centers.
Background
A large logistics sorting center in China spans approximately 50,000 square meters. The core sorting area adopts a cross-belt sorting system with a total sorting line length of 800 meters, equipped with 6 sorting lines and processing over 500,000 parcels daily. The sorting system includes 60 induction stations and 200+ mobile sorting carts.
Currently, induction stations need to transmit parcel destination, weight, and dimension data to the sorting control system in real time, while mobile sorting carts require seamless roaming along the 800-meter sorting lines to ensure real-time interaction of dispatch commands, position information, and status feedback. However, the sorting center features dense metal frames and numerous motors, causing severe electromagnetic interference. Conventional wired communication is complex to deploy and cannot adapt to the mobile requirements of sorting carts, while traditional wireless communication suffers from insufficient stability due to motor interference, affecting overall sorting efficiency.
The customer urgently needs to build a highly reliable communication network to ensure real-time data transmission from induction stations and seamless roaming communication for sorting carts.
The Challenges
Signal Obstruction
Dense metal frames and equipment supports inside the sorting center severely obstruct wireless signals, creating communication blind zones and affecting signal stability for carts at various positions along the sorting lines.
EMI
Motors, variable-frequency drives, and other high-power equipment inside the sorting center generate strong electromagnetic interference. Traditional wireless solutions lack sufficient anti-interference capabilities, resulting in high network latency and data jitter that affect real-time dispatch command delivery.
Roaming Dropouts
200+ mobile sorting carts operate at high speeds along 800-meter sorting lines, requiring rapid AP handovers. Traditional solutions suffer long roaming handover times, causing frequent dropouts and loss of dispatch commands during cart movement.
Wired Difficulties
Sorting carts are continuously moving, making wired communication unsuitable. Traditional cabling requires extensive cable deployment along sorting lines, with complex installation, difficult maintenance, and negative impact on sorting area cleanliness.
Solution Architecture
Core Layer — KXS205G 5-Port Gigabit Switch
Deploy the KXS205G switch in the sorting center control room as the core communication node, directly connecting induction station scanning cameras and the sorting system industrial PC to enable bidirectional real-time transmission of scanning data and industrial PC commands. Through VLAN partitioning, induction station data transmission and industrial PC control commands are separated into independent channels to prevent data congestion. The KXS205G features IP40 protection design, operating temperature range of -30℃ to 75℃, supports 24/7 uninterrupted operation, and offers MTBF ≥ 600,000 hours.
Access Layer — KXA5100-5NL Wireless Access Point (AP)
Deploy KXA5100-5NL wireless access points (APs) along the circular track of the cross-belt sorting line to achieve full signal coverage across the sorting belt area. The AP supports the 4900MHz–6100MHz ultra-wide frequency band and Dynamic Frequency Selection (DFS), automatically avoiding 2.4GHz band electromagnetic interference in the sorting center to provide a stable foundation for cart imperceptible roaming communication. The AP supports 100+ concurrent terminal connections, meeting the collaborative operation needs of 200+ sorting carts and induction station equipment. With IP67 protection rating and -40℃ to 80℃ wide-temperature design, it easily handles the dust, vibration, and other harsh conditions in the sorting center.
Client Layer — KXC1100-5N Wireless Communication Module
Each cross-belt sorting cart is equipped with a KXC1100-5N wireless communication module as an access layer terminal. The module features a compact design for easy installation inside the cart, with a built-in high-performance antenna ensuring stable signal transmission. It supports rapid handshake with KXA5100-5NL APs. When the current AP signal weakens during cart movement, it automatically switches to an adjacent AP within ≤10ms, achieving “imperceptible roaming.” It supports multiple communication protocols with strong compatibility for easy system integration, and features an automatic reconnection function to ensure data transmission continuity.
Recommended Products
KXA5100-5N(L)
- Wireless Access Point
- Data Rate: 300Mbps
- Concurrent: 100unit
- Distance: 200 meters
KXC1100-5N
- Wireless Client
- Data Rate: 300Mbps
- Distance: 100 meters
KXS205
- Industrial Switch
- Non-Managed
- 100Mbps/1000Mbps
POE Optional
KXS208
- Industrial Switch
- Non-Managed
- 100Mbps/1000Mbps
POE Optional
Technological Advantage
Zero-Interruption
- 200+ sorting carts with cross-AP roaming handover ≤ 10ms, no dropouts and no packet loss throughout operation
Low Latency
Induction station to industrial PC data transmission latency < 50ms, real-time and reliable command delivery
Anti-Interference
DFS dynamic frequency selection ensures stable signal in high electromagnetic environments, sorting efficiency unaffected
Flexible Deployment
- Wired-wireless integrated architecture eliminates extensive cabling, comprehensive cost reduction
Get a Tailored Solution
Tell us about your operational environment — our engineers will review your requirements and provide a customized wireless communication solution, typically within 48 hours.
✓ Free site survey support
✓ Solution design included
✓ Samples available upon request
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