Andon systems come in two fundamental architectures: wired and wireless. Each approach has distinct advantages and trade-offs that affect installation, operation, and long-term flexibility.
This article compares the two approaches across key dimensions—installation, reliability, maintenance, scalability, and cost—to help you determine which is right for your facility.
How Wired Systems Work
Wired Andon systems connect call buttons to a central controller through physical cables.
The architecture resembles traditional nurse call or intercom systems:
- Cables run from each button location to a central panel
- Signals travel through dedicated wiring
- The system typically integrates with facility electrical infrastructure
How Wireless Systems Work
Wireless Andon systems use radio frequency (RF) communication between components.
The typical wireless architecture includes:
Call buttons that transmit RF signals when pressed. Buttons are battery-powered and require no wiring—just mounting in position.
A transmitter that receives button signals and relays them to pagers. Industrial transmitters cover significant range:
"The transmitter gives you a range of about three quarters of a mile, allowing it to go from either end of the building."
Pagers or watches that receive alerts from the transmitter. Responders wear these devices and receive vibration or audible alerts.
Optional signal repeaters that extend range when needed:
"The call buttons have a range of 100 to 150 feet to the transmitter. If it's further than that, if it's in a different level, or if you have a button in a different building, then you have to add a signal repeater."
Power requirements are minimal:
"That transmitter's just hooked up to a power source."
No network infrastructure is required for basic operation—just a standard electrical outlet for the transmitter.
Pros and Cons of Wired Systems
Advantages of Wired Systems
Very reliable signal transmission. Wired connections don't suffer from radio interference, signal degradation, or range limitations. Once installed and working, wired systems are extremely stable.
No battery management. Wired buttons draw power from the cable. There's no need to monitor, charge, or replace batteries.
No range considerations. Anywhere you run cable, you have full functionality. Distance from a central controller doesn't affect performance.
Integration with existing infrastructure. Facilities with existing wired systems (emergency alert, intercom, etc.) may be able to leverage that infrastructure.
Disadvantages of Wired Systems
Complex and expensive installation. Running cable requires conduit, electrical work, and often professional contractors. Installation disrupts operations and takes significant time.
Difficult to relocate or reconfigure. Moving a wired button means moving the cable. Production line changes, equipment relocations, or layout modifications require rewiring.
Fixed infrastructure. The wiring defines what's possible. Flexibility is limited by where cables were originally run.
Disruptive installation process. Cable runs may require shutting down areas, cutting into walls or floors, and coordinating with facility maintenance.
Pros and Cons of Wireless Systems
Advantages of Wireless Systems
Easy installation. Mount buttons where needed, plug in the transmitter, configure the software. No electricians, no conduit, no cable runs.
"You can place that in the production floor in a central location near those buttons to maximize your distance."
Flexibility and reconfiguration. Moving a button means physically relocating it and updating the software. Layout changes don't require rewiring.
Non-disruptive deployment. Wireless systems can be installed during normal operations without shutting down production areas.
Lower upfront cost. No wiring labor or materials. Equipment costs are typically lower than wired alternatives.
Scalability with range options. Different transmitter sizes accommodate different facility sizes:
"The bigger transmitter, because it's usually used for manufacturing and it covers a good distance around... the one that you currently have is for small office for just the immediate area."
Disadvantages of Wireless Systems
Range requires planning. Wireless systems have limits. Large facilities or those with multiple buildings may need signal repeaters. Obstructions (thick walls, metal structures) can affect range.
Battery management. Responder pagers require charging:
"Battery life for pagers is estimated at 8-12 hours depending on usage."
This creates an operational consideration:
"Make sure that each one is charged for at least that shift."
Equipment can move—sometimes unintentionally. Wireless devices are portable, which is usually an advantage. But:
"Some of the equipment, I don't know, they've relocated and I don't even know where it's at."
Buttons and pagers can be moved, misplaced, or lost. This requires some operational discipline.
Signal interference potential. Though rare in modern systems, RF interference is theoretically possible in environments with heavy radio traffic.
Installation Considerations
Wired Installation
Installing a wired Andon system involves:
- Conduit planning: Determining cable routes from each button location to the central controller
- Electrical coordination: Working with facility electricians and potentially outside contractors
- Downtime scheduling: Many installations require shutting down areas during cable runs
- Permanent infrastructure: The installation becomes part of the building
Wireless Installation
Installing a wireless system involves:
- Mounting buttons: Adhesive, screws, or magnetic mounting at each station
- Positioning transmitter: Central location with power outlet
- Configuring software: Programming buttons, pagers, and escalation rules
- Testing: Verifying range and signal quality throughout coverage area
Many facilities can self-install wireless systems without vendor technicians on site.
Reliability and Maintenance
Wired System Reliability
Once installed and tested, wired systems are extremely reliable:
- Signals don't degrade over time
- No interference concerns
- Few failure points once operational
Wireless System Reliability
Wireless reliability depends on proper setup:
- Transmitter and buttons within specified range
- Repeaters positioned correctly if needed
- Adequate battery management for pagers
Ongoing maintenance includes:
- Charging pagers daily
- Replacing button batteries (typically 1-2 year lifespan)
- Occasional device replacement
Scalability Differences
Scaling Wired Systems
Adding stations to a wired system means running more cable. Each new button requires:
- Cable from station to controller
- Potentially new conduit
- Electrical work
Scaling Wireless Systems
Adding stations to a wireless system means adding devices:
- Mount new buttons
- Program in software
- Add repeaters if expanding beyond current range
Cost Comparison
Wired System Costs
Higher installation: Labor and materials for cable runs often exceed equipment costs. Professional installation is typically required.
Lower ongoing costs: No batteries to replace, no charging infrastructure. Once installed, operating costs are minimal.
Expensive expansion: Each new station carries significant installation cost.
Wireless System Costs
Lower installation: Equipment costs dominate. Self-installation is often possible.
Ongoing operational costs: Battery replacement, chargers, occasional device replacement.
Economical expansion: Adding capacity is straightforward and relatively inexpensive.
Over a 5-10 year horizon, total cost of ownership may be similar—but the cost profile differs significantly.
Decision Framework
Choose Wired When:
- Facility layout is permanent. If production lines and workstations won't move, wired infrastructure makes sense.
- You're building new or renovating. Wire installation during construction is far less expensive than retrofitting.
- Maximum reliability is critical. Environments where any signal uncertainty is unacceptable.
- You have existing wired infrastructure. Leveraging existing cable runs reduces cost.
Choose Wireless When:
- Flexibility matters. Production environments that reconfigure regularly benefit from wireless mobility.
- Layout may change. If you expect equipment relocations, new lines, or facility modifications, wireless accommodates change.
- Quick deployment is needed. Wireless systems can be operational in days, not weeks.
- Budget is limited. Lower upfront cost makes wireless more accessible.
- Retrofitting existing facility. Adding capability without major construction.
Frequently Asked Questions
Which is more reliable?
Both can be highly reliable. Wired systems have an edge in environments with heavy RF interference or extreme distances. Modern wireless systems are reliable for the vast majority of manufacturing applications.
Can wireless cover large facilities?
Yes, with proper planning. Industrial transmitters cover up to three-quarters of a mile. Signal repeaters extend range further. Very large facilities may need multiple repeaters, but coverage is achievable.
What about interference?
Modern wireless Andon systems operate on frequencies designed to minimize interference. In typical manufacturing environments, interference is not a practical concern. Facilities with unusual RF environments should discuss with vendors.
Can I mix wired and wireless?
Some vendors offer hybrid solutions. If you have existing wired infrastructure in part of your facility, you may be able to add wireless coverage in other areas. Discuss integration options with vendors.
Making Your Decision
The wired vs. wireless decision comes down to priorities:
- Prioritize reliability and permanence → Consider wired
- Prioritize flexibility and speed → Consider wireless
- Prioritize low upfront cost → Wireless typically wins
- Prioritize low ongoing maintenance → Wired typically wins
Wired systems remain appropriate for new construction, high-reliability requirements, or facilities with existing wired infrastructure to leverage.
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