We are honored to collaborate with Liebherr, a global leader in industrial manufacturing and logistics, to deploy an advanced PLC (Power Line Communication) smart warehouse lighting system. This project demonstrates how modern industrial facilities can achieve high-efficiency, low-maintenance, and fully connected lighting control by utilizing existing electrical infrastructure.
Project Overview
Liebherr required a lighting solution that could improve energy efficiency, enable centralized remote management, and support rapid scalability across different warehouse zones. Traditional communication cabling was costly and difficult to integrate into their operational environment, especially in high-bay storage areas and continuously running logistics lines.
Our PLC-based intelligent warehouse lighting solution delivered exactly what they needed—by using the existing power lines to transmit data and control signals, eliminating the need for rewiring while keeping installation fast and clean.
Key Features of the Liebherr PLC Warehouse Lighting System
1. Centralized Cloud-Based Lighting Management
- Full control of all warehouse lights via a cloud dashboard and mobile app
- Real-time switching, dimming, grouping, and scheduling
- Energy consumption analytics and operational reports
- Multi-user access with role-based permissions
2. High-Bay PLC Dimming Nodes
Each LED high-bay luminaire is equipped with an industrial-grade PLC dimming module supporting:
- 0–100% dimming
- Telemetry reporting (voltage, current, driver health, temperature)
- Addressable control per fixture or per zone
3. No Extra Cabling Required
The system communicates through the existing power network, which enabled:
- Zero additional data wiring
- Fast deployment with minimal downtime
- Lower installation and infrastructure cost
- Easy expansion to future facility areas
4. Smart Warehouse Automation Integration
The PLC lighting network integrates with Liebherr’s existing warehouse systems:
- Automated brightness adjustment based on occupancy sensors or forklift movement
- Scheduled dimming for idle zones
- Adaptive illumination during night-shift operations
- Alarm notifications for abnormal energy spikes or device failures
5. Reliability for Industrial Environments
Warehouses often contain equipment that creates electrical noise. To ensure signal stability, the project includes:
- PLC isolator controllers for segment protection
- Line filters to suppress EMI from conveyors and machinery
- Surge protection devices for power spikes
- Redundant PLC paths in large warehouse zones
Operational Benefits for Liebherr
✔ Significant Energy Savings
Dynamic dimming, zone control, and scheduling help reduce energy use by 30–50%, especially during off-peak hours.
✔ Lower Maintenance Costs
Remote diagnostics allow maintenance teams to locate and fix issues without unnecessary inspections. Fault messages include:
- Lamp failure
- Driver overheating
- Unusual current consumption
- Power interruptions
✔ Improved Lighting Uniformity & Worker Safety
Adaptive illumination ensures consistent brightness in picking aisles, loading zones, and high racks, supporting safe operations around forklifts and automated equipment.
✔ Scalable for Future Warehouses
Because PLC uses the existing power network, Liebherr can replicate the same solution in new facilities with minimal effort.
Project Impact
The Liebherr PLC smart warehouse lighting project demonstrates how industrial facilities can evolve into connected, intelligent, and sustainable environments. By merging PLC communication with cloud-based management, Liebherr now benefits from:
- Higher lighting reliability
- Automated smart control
- Reduced operational costs
- Enhanced workplace visibility
- A foundation for future digital transformation
This successful deployment further validates how our PLC lighting technology empowers global enterprises to modernize facilities efficiently—without complex wiring or system disruption.
