Assembly and Robotics

Banner Helps Improve Efficiencies in Assembly and Manufacturing

A broad range of assembly methods are adopted by manufacturers to meet their production requirements for volume, product mix and cost structure. From manual work stations where operator experience is fundamental for product assembly to highly automated production lines utilizing robotics in the manufacture of goods, maximizing production efficiency and ensuring product quality is critical to a manufacturer’s competitiveness in the global market place.

Every day, solutions from Banner Engineering are helping manufacturers gain a competitive edge. Our industry knowledge and expertise in sensors, safety control, wireless I/O and LED lighting is helping manufacturers enhance their production processes, address machine safeguarding requirements and ensure high levels of product quality. We have a solid network of knowledgeable channel partners and the largest team of applications engineers in the industry, all able to draw on a catalog of over 30,000 products designed and developed to solve problems.

Assembly and Robotics

Assembly and Robotics

Maximizing production efficiency and ensuring product quality is critical to a manufacturer’s competitiveness. Products and solutions from Banner help manufacturers enhance their production processes, address machine safeguarding requirements and ensure high levels of product quality.

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Featured Applications

High-Quality LED Lighting for Automation Illumination

Banner’s WLB32 is an LED industrial light bar with easy mounting options, such as snap clips and a choice of magnetic or angle brackets. LED lights can be easily be cascaded to properly illuminate the manufacturing line. Banner’s LED lighting is an ideal replacement for conventional fluorescent lighting.

Part Pick Indication for Small Bins

To reduce the risk of error in an assembly operation, a one-piece EZ-LIGHT PVD pick-to-light sensor with a 400 mm range is interfaced with a process controller programmed with the correct assembly sequence. The controller makes the PVDs light up in the correct order, to show the assembler which part to pick. After the PVD detects that the assembler's hand has entered and left the bin, the controller signals the PVD of the next bin in the pick sequence to light up.

Wireless Call for Parts

A system of Banner’s TL70 wireless modular tower lights and K50 touch buttons provides an efficient, easy way to communicate a call for more parts with a forklift driver. When a workstation is almost out of cartons, the operator touches the ergonomic K50 touch button which changes the status on the connected TL70 wireless tower light to red.

Area Guarding for Robotic Cells

Safety laser scanners work well for safeguarding applications where user access and protection are equally important. Banner’s AG4 Safety Laser Scanner with a 190º scanning angle fits nearly any shape and can evaluate an operator’s position by range and rotational angle. Its flexibility allows for new safeguarding shapes when work cell dimensions and parameters change.

Detecting Black Parts on Black Door Panel

Differentiate between foam and poor contrast background

Bright Indication in Ambient Light

When a window is located directly behind a cabinet, extremely bright, long lasting LED indicator lights can provide highly visible indication throughout the day. Banner’s EZ-LIGHT K50 Beacon is perfect for many indication status applications, especially in this cabinet because the beacon is highly visible even during daylight and is extremely durable with long-lasting, energy-efficient LEDs.

QS18 Series

All purpose photoelectric sensor with universal housing design and 18 mm threaded barrel is an ideal replacement for hundreds of other sensor styles.

Q4X Series Rugged Laser Distance Sensor

Rugged Q4X laser distance sensor solves many challenging applications and comes in a rugged IP69K rating with FDA food grade stainless steel housing.

Fiber Optic Amplifier: DF-G2 Series

Designed to achieve the world’s fastest response rate, the DF-G2 fiber optic amplifier can achieve 10 microsecond response time with 5 microsecond repeatability. Output options include discrete, dual discrete, and IO-Link communication.

14 & 30 mm Resolution Safety Light Curtains

Safety light screens protect personnel from injury and machines from damage by guarding points of operation, access, areas and perimeters.

50 mm Illuminated Touch Buttons: K50 Series

K50 Series touch buttons combine a large, bright indicator with solid-state, touch-activated switching capability, ideal for lean manufacturing and bin-picking operations.

Success Stories

LED Lights Illuminate Control Cabinet

An equipment manufacturer builds test and measurement machinery for the auto industry. Operators access machine systems through the control cabinet. Intense illumination of the cabinet facilitates machine maintenance and management. Multiple AC powered fluorescent light fixtures had been used for this task.

Vision Sensor to Read QR Codes [Success Story]

Prior to installation, engines and transmissions are coupled together on the assembly line. A worker using a hand held bar code reader scans the QR code on each transmission. The codes are small, have minimal quiet zones and are dense with embedded information. Additionally, the bar code readers have a limited range. Combined, these factors made scanning the QR codes difficult, adding time to the assembly process and diverting labor resources.

Sensors to Measure Movement Range

During assembly, inspections are conducted to measure seat height adjustment, forward and rearward movement, and upright and recline motion. Two sensors are used for each inspection. The sensors are deployed off the conveyor line to ensure easy access to and the free movement of the seats. At its maximum range during inspection, a seat may be as far as a meter away from the sensors.

Streamlining Call for Parts or Service [Success Story]

To improve efficiency, assemblers at work stations need a way to call for parts and service that doesn’t involve them leaving their work stations. Getting parts more quickly would improve production efficiency, and using a system of remote indicators would let the supervisors to see the status of each work station, allowing the supervisors to fix production problems quickly and to collect production metrics.

Communication in a Busy Manufacturing Site [Success Story]

As more components pass through the oven, keeping pace with the flow of items to be unloaded becomes increasingly difficult. Congestion in the sortation area builds. Items can easily be misdirected or even damaged. A pause in the flow of parts allows the unloading operator to correct mistakes and clear a pickup station. However, the distance between the unloading and loading areas as well as ambient interference from surrounding machinery complicates communication between operators.

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Assembly and Robotics

Banner Helps Improve Efficiencies in Assembly and Manufacturing

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