Systemizing & Synchronizing LED Digital Counters for redundancy on all production lines

In action, this system was deployed by Justrite Manufacturing LLC, where it was used to keep track of package counts on an assembly line. With the synchronized master-secondary setup, multiple stations across the factory floor could view the same live package data, ensuring accurate tracking and improved workflow visibility.
The DC-40C-PKG Master-Secondary Package Counter is designed to streamline package counting and provide synchronized visibility across multiple locations. This custom order integrates sensors, remote controls, and LED displays into a reliable system built for demanding environments such as manufacturing and assembly lines.
At the core of the system is a diffused reflective sensor, which detects solid objects as they pass by. Each time a package crosses the sensor’s line of sight, the counter increments by one. The system includes remote switches mounted in a sealed junction box, connected with 25 feet of cable, that allow for decrementing counts and resetting the display back to zero.
The display itself is a four-inch, four-digit, all-aluminum enclosure designed for visibility and durability. This setup is configured as a master-secondary system, meaning one display acts as the master while the other mirrors its data as the secondary. With 50 feet of cabling between units, the system ensures synchronized, real-time data transmission. A flashing LED indicator confirms active communication between displays. If data transmission is interrupted, the indicator stops flashing, signaling a loss of data.
Key Features of the DC-40C-PKG:
- Reflective sensor with millisecond response time for fast and accurate counting
- Environmentally sealed remote switches for decrement and reset functions
- Four-inch, four-digit LED displays housed in all-aluminum enclosures
- Master-secondary synchronization via wired connection with visual data confirmation
- Scalability – configure any LED display as a master to drive additional secondary units
- Wired support for up to 100 secondary displays and wireless capability extending up to 1500 feet with unlimited secondary units
The DC-40C-PKG demonstrates how a customized, synchronized display system can provide precision and reliability in industrial operations. Whether wired or wireless, this package counter delivers scalability and redundancy, making it a versatile solution for modern manufacturing environments.
See the Justrite counters in action
The counters DC-40C-PKG
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