Photo: sensor on the structure above a stack, portrait 3:4
01
Sensor above the stack
Measures the distance to the top pallet. One sensor per stack, up to eight per station, mounted on the hall structure above the station.
Pallet stack measurement
Every stack counted. In real time.
A sensor above the station measures stack height and converts it to a pallet count. The web panel and signal tower show shortages and overflows.
Try it: add or remove a pallet
Distance2500 mm
Pallets on stack0
StatusBelow minimum
Mounting 2500 mm, pallet 140 mm, minimum 3, warning up to 5, capacity 14.
Example deployment
112measuring stations in one logistics centre
2023first commissioning, extended with more stations in 2025
1–8stacks under one station controller
0dependence on the internet, runs on the plant network
Figures from a working site, not from a datasheet — with one exception: the range of 1–8 stacks per controller is what the system can do, the rest is the state of that installation. We do not name the client; references are shared directly on request.
System components
From the sensor to the screen in the hall
Photos from a live installation. The full-size panel is further down.
Photo: monitor with the panel in the hall, 4:3
02
Screen in the hall
A monitor under the ceiling shows the panel where the forklifts work. Tile colour reads from the far end of the aisle, no walk to a computer.
Photo: whole station, portrait 3:4
03
Station
Sensor high above the stack, pallets below it. No gates, no scanning: the forklift drops and picks pallets as it always did.
04
Station controller
Collects sensor readings, filters noise against pallet thickness and sends the measurement to the server with signal strength and operating temperature.
05
Signal tower
Red, yellow and green lamp plus a siren. Polls the server and sets colour, flashing mode and beep count on its own. A button silences the alarm for a set time.
06
Server and web panel
An application on a computer in the plant network. Tiles, bars or squares, sections, quantity thresholds, user roles and a JSON API for WMS systems.
Measurement logic
How a stack becomes a number
The scene below replays the full cycle: measure, convert, evaluate thresholds, signal. Pause it and step through.
The sensor measures the distance to the top of the stack. An empty stack is a known distance to the floor.
Web panel
One screen, the whole pallet stock
The same state in three views. Pick the layout that reads from the far end of the hall.
Three views
Tiles with pallet counts, stack height bars or squares. The view is remembered per user.
Sections and thresholds
Stations grouped into sections in a set order. Separate minimum and full-stack thresholds for every sensor.
Quiet hours and mute
A schedule for switching the siren on and off. A button in the hall silences the alarm for a configured time.
History and API
Every reading stored in the database. Station state available through a JSON API for WMS and ERP systems.
Screenshot: tile view
Example view: bars
Example view: squares
Example views showing the same stock in three layouts. The panel is designed for each specific warehouse — section layout, station names, thresholds and colours are set the way they read on that particular floor. What you see here illustrates the principle, not a finished client screen.
Specifications
Operating parameters
Defaults from live installations. Every threshold and dimension is configured per stack.
2500 mm
Sensor mounting height
Nominal value, entered per sensor at commissioning.
140 mm
Pallet thickness
Default. For EUR pallets enter 144 mm, for other types their actual height.
14
Pallets per stack
Default stack capacity. The full-stack threshold is set separately.
1 to 8
Sensors per station
One controller handles up to eight adjacent stacks.
3
Shortage alarm threshold
Below minimum: red tile and siren. Just above minimum: yellow warning. All three thresholds are set per sensor.
15 min
Silent sensor detection
No reading for more than 15 minutes flags the stack as late.
str + temp
Diagnostics in every reading
Signal strength and controller temperature are stored with the distance.
LAN
On-premise server
PHP and MySQL on a computer in the plant network. No cloud, no subscription.
matched
Distance sensor
Matched to the station: range to the mounting height, beam angle to the stack width, enclosure rating to the conditions on the floor. The software is not tied to one model — it handles different sensors, so replacing or upgrading one changes nothing in the panel or the database.
in-house
Station controller
Designed and built by FelixCom, in an industrial enclosure. Power and the communication link are matched to the installation — where a cable cannot be run, the station works wirelessly. The firmware and the protocol are ours, so extending the system does not depend on somebody else's product lifecycle or availability.
Deployment
Deployment in four steps
1
Site survey
We measure the stations, the structure height and agree the pallet types.
2
Installation
Sensors, controllers and the signal tower in the hall. The server on a computer in the plant network.
3
Configuration
Sections, minimum and full-stack thresholds, siren schedule, user accounts.
4
Commissioning
Calibration of every sensor on an empty and a full stack. Team training.
Reference
Proven in continuous operation
A logistics centre in Poland. 12 measuring stations under sensors. Running since July 2023, extended with more stations in July 2025, same server, same measurement database.
- Mounted on the existing hall structure, no station rebuild
- Server on the client's computer, in their network, no cloud
- Extended with more stations without replacing existing ones
- Design, installation, commissioning and service in one hand
112measuring stations in one logistics centre
2023first commissioning, extended with more stations in 2025
FAQ
Questions we hear most often
How does the system count pallets?
A sensor above the stack measures the distance to the top pallet. The controller subtracts this distance from the mounting height and divides by pallet thickness. The result is the number of pallets in the stack.
Does it handle different pallet types?
Yes. Pallet thickness is entered separately for each sensor, so one station can hold stacks of different pallet types.
What does a shortage alarm look like?
First a warning: tile and lamp turn yellow as the stack approaches the minimum. Below minimum the tile turns red, the tower lights its red lamp and beeps. Thresholds, beep count, flashing mode and quiet hours are set in the panel.
Does any data leave the plant?
No. The server runs on a computer in the local network, sensors and the tower connect to it over LAN. The internet is not needed for operation.
Can it connect to a WMS?
Station state is available through a JSON API. Integration with a specific WMS or ERP is quoted after analysis.
Contact
Request a quote for your warehouse
Tell us how many pallet stations you have and which pallets you use. We reply within a working day.
Prefer to call?+48 575 101 210