Automotive Solutions

Temperature Sensor Detects Defrost Wires

An automotive manufacturer was rejecting a supplier’s shipment of rear window assemblies due to faulty defroster grids. The supplier’s existing test procedure measured current draw across the entire heating system to detect an overall failure, but it could not detect the subtle impact of a single heating wire being broken. The window supplier partnered with a Michigan-based machine automation company to create a better test fixture—one that can verify each defrost wire heats to specification prior to shipping.

Wireless Motor Temperature Control and Monitoring

Instead of installing I/O transmission cabling, use a 10 to 30V dc powered Sure Cross Node and a Banner T-GAGE temperature sensor. When using host control systems, the Sure Cross Gateway transmits the temperature to the plant control room using a digital output related to temperature setpoints within the sensor. The motor is powered down or up based on these temperatures. When using a Gateway Pro as the wireless master device, the data ca be logged and alerts sent out to notify maintenance personnel when a motor is performing outside expected parameters.

Equipment Monitoring from a Supervisor's Station

Provide at-a-glance machine status indication and send machine status information to a wide range of devices.

Restocking Assembly Stations for a Continuous Workflow

Restock assembly stations before components run out without overstocking.

Call for Pickup from an Assembly Station to an AGV

• Remove completed pallets from assembly stations quickly • Enable direct communication from assembly stations to AGVs • Improve process efficiency using turnaround time data to

Warning Indication where Obstructions Limit Visibility

• Provide high-visibility warning indication • Minimize risk to staff in high-traffic forklift area • Facilitate the flow of traffic through an area with visual obstructions

Optimizing Equipment Effectiveness with Remote Monitoring

Provide instant visual communication across a busy plant floor.

Environmental Monitoring inside a Machine Control Panel

Identify small problems before they become major issues that impact machine performance and uptime.

Status Indication on Driverless Vehicles

The K50L domed 50 mm indicator light works well for status indication on autonomous shuttle buses. The buses operate on short distances in outdoor environments that exposed the bus technology to a variety of weather conditions. The rugged K50L indicators are rated IP67 and IP69K to withstand water ingress in the harsh environment.

Easy Panels with Multicolor Indicators and Touch Buttons

S22 Pro Series touch buttons and indicators simplify control panel design and improve operator experience and performance. Pro Editor software expands the built-in display capabilities available with the S22 Pro Series, enabling custom displays.

Assembly Timer at Busy Work Station

K50 Pro touch buttons with IO-Link communication display takt time within workers' sightlines so that the assembly pace stays on track and meets production goals.

Monitor Hydraulic Power Units

Easily monitor the pressure, current, oil temperature, and motor vibration/temperature of hydraulic power units and other hydraulic machinery. Snap Signal products connect sensors of various types and convert their signals to Modbus data for real-time condition monitoring.

Monitor Leaks in Your Critical Applications

Monitor leaks in your critical applications and receive real time alerts when they occur.

Bring In IO-link Sensor Data for Tank Level Applications Wirelessly

Wirelessly integrate IO-link sensor data for tank level monitoring with Banner's DXM controllers and T30R sensors for accurate, remote data analysis.

Detect Installed Glass on Automobile

Sensor solutions to detect the presence of a moonroof on an automobile assembly line where extended range capabilities are required.

Manual Load Weld Cell

Banner’s EZ-SCREEN® series safety light curtain system is a well established solution for the harsh requirements of welding equipment. With the ability to cascade (series connect) multiple segments together, configurations such as this horizontal/ vertical pair are easily implemented with standard hardware (no master/slave models).

Perimeter Guarding on a Tube Bending Machine

Widely spaced SGS safety grid platform light screen economically protects the perimeter of a work area. The grid is far enough from the hazard that motion has time to stop if a person or object passes through the grid.

Area and Gate Guarding on Automotive Assembly Line

Integral hinge will stop conveyor once the gate is opened and the grid is muted when gate is opened.

UV Barcodes for Traceability

Before shipping to the brand assembler, a supplier of auto visors needs to verify that Data Matrix UV barcodes have been printed on each visor’s safety label. The customer turned to Banner to read invisible 2D Data Matrix barcode and send data via Ethernet IP to a PLC for traceability/error proofing.

Vision Sensor to Read QR Codes

iVu Plus BCR Gen 2 with 25 mm Micro Lens replaces hand held barcode readers to collect data from dense, difficult-to-read QR codes on vehicle transmissions. A WL50S high-intensity LED spot light illuminates the target area.

Reading DPM Codes on Automotive Components

Direct part mark (DPM) codes can be small, complex, and difficult to distinguish from the material they are etched into. The ABR 7000 barcode reader is available in models specifically designed to solve challenging low-contrast and DPM applications like this.

Operator Guidance Solution

A Henshaw customer manufactures drivetrain and powertrain systems for the automotive industry. The company had experienced productivity losses due to errors in the assembly of transmission valve bodies. Henshaw was tasked with developing a system that would reduce errors and improve the assembly process.

Kitting Operation with Gloves

Banner’s fixed-field K50 indicator detects gloved hands , sensing when operators select the correct parts during the kitting process. The K50 indicator’s logic function is then able to notify the operator that he/she picked correctly by changing from green to yellow—additional colors can be selected to suite to the manufacturer’s preference. The K50’s ability to detect black gloves is especially important for lean manufacturing processes where workers typically wear dark gloves.

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.

Long Bin Pick-to-Light

The EZ-LIGHT PVA pick-to-light sensors provide a reliable error-proofing solution for various operation systems. The light indicate to assemblers which items to pick and in which order to pick them.

Multiproduct Light-Guided Assembly Station

PTL110 pick-to-light devices on a multiproduct assembly station are a highly effective way to prevent errors and speed up build time. The optical sensors on PTL devices detect hands as they pass by, confirming that a pick was made.

Light-Guided Kit Building at Large Station

Manual kit building at large stations can be time-consuming and subject to human error, especially if storage racks are difficult to navigate. The PTL110 series pick-to-lights are scalable for large systems and highly versatile to complete numerous tasks.

LED Lights Illuminate Control Cabinet

Operators access machine systems through the control cabinet and need Intense illumination of the cabinet facilitates for maintenance and management.

Superior Light Distribution with LEDs

American Hoffmann Corporation chose WLB32 LED light bars to illuminate work areas, enclosures and control cabinets, replacing fluorescent light fixtures. The superior light distribution offered by the WLB32 LED lights lights, as well as the ease of installation were key factors in the company's decision.

Detection of Surface Imperfections with Green LED Lighting

Learn how green LED task lights enhance visibility of surface imperfections on manufacturing materials.

High-Quality LED Lights Improve Quality Inspection

Automotive inspection requires consistent, bright light with minimal glare to inspect automotive parts. Increased lighting can improve worker productivity and reduce eye strain.

High-Quality LED Lighting for Conveyor Illumination

Finding a high-intensity, ultra-bright lighting solution for manufacturing can be challenging. Since multiple lights are required to properly illuminate areas on a conveyor, a simple mounting option to connect lights together is needed.

Assembly Timer Indication at Automotive Assembly Station

The TL50 Pro tower light helps assemblers meet expected cycle times and support overall takt time requirements.

Dual Output Status Indication

The S15L Series In-Line Sensor Status Indicator is a two color indicator light that indicates power and output status. Its inline connection, over-molded design and bright indication create a cost-effective solution that can be applied to most 4- or 5-pin devices with an output.

Inspecting Small Connectors

An automotive supply company makes a range of vehicle systems. Their seating systems combine structure and design with features that enhance comfort and safety. Weight sensors installed on the underside of the seats work in coordination with vehicle safety systems to determine the size and position of a seat occupant. These factors affect how or if airbags will be deployed in the event of an accident.

Sheet Metal Thickness Measurement

Precise and consistent sensing while material moves down a conveyor measuring thickness at micron levels.

Sensors to Measure Movement Range

During assembly, inspections are conducted to measure seat height adjustment, forward and rearward movement, and upright and recline motion.

Precise Crankshaft Runout Measurement

Crankshaft runout measurements must be monitored continuously to ensure that they meet tolerance requirements. Learn how LM Series laser measurement sensors solve this difficult application.

Ply Orientation Inspection

Before the operator activates a tire-building machine to form a tire, a PresencePLUS P4 OMNI 1.3 vision sensor inspects the plies to make sure that pieces with opposite biases alternate in the stack. If two pieces with the same bias are stacked together, the formed tire proceeds through the manufacturing process, then fails balance testing and must be scrapped.

Run Bar Provides Operator Guidance

A leading machine manufacturer builds workstations designed for accurate, timely and cost-effective battery cell assembly. A value added component of the workstations is an operator guidance device that does three jobs: enables assembly processes to start and stop, indicates parts to be picked and installed, and completely stops line operation if emergencies occur. When it became too costly for the OEM to construct and mount these devices themselves, they turned to Banner to craft an all-inclusive solution. To honor the time line requirements of their customer—a major tier two battery supplier—the OEM needed the solution in eight weeks.

Engine Block Positioning

Banner’s L-GAGE LH Laser Displacement Sensor is ideal for applications where exact positioning of a part is crucial. The L-GAGE LH Series consistently looks at dark targets on micron levels. Banner’s laser displacement sensor is extremely accurate for precise positioning applications, including engine block positioning. The sensor can take measurements on virtually any surface, such as cast iron or aluminum alloys, which are often used for the manufacturing of engine blocks.

Part Removal Verification in Automotive Assembly

In an automotive assembly plant, temporary pins—called grenade pins—are used to attach some parts temporarily. To make sure the grenade pins are removed, the inspection station includes a container for the pins that is equipped with an EZ-LIGHT PVA pick-to-light sensor.

Rubber Washer Detection on Engine Block

Banner’s Q4X versatile laser sensor is ideal for presence/absence detection even in challenging applications with small height changes such as confirming a small black target is present on a shiny metal part. The washers should be present in the cast aluminum engine block, and if the Q4X detects a slight height difference, even as small as 1 mm, it will send a signal to alert operators a rubber washer is missing or there are multiple washers present. The Q4X can detect duplicate rubber washers with its unique windowing capability while in foreground suppression mode.

Detecting a Line of Adhesive on a Vehicle Door Panel

A VE Series Smart Camera, configured to use the bead tool, inspects each door panel for the presence and consistency of adhesive. The camera has a wide field of view and a 2 MP imager capable of detecting even slight inconsistencies in the amount of adhesive applied.

Detecting Black Parts on Black Door Panel

Since door panels are often dark colors such as black or gray, and the foam used to eliminate rattles and provide stiffness is generally black, it can be difficult for standard sensors to differentiate between foam presence and absence due to poor contrast.

Multiple Point Inspection on Stamped Metal Parts

To verify the expected number of holes exists on a small metal part, the iVu Plus TG Image Sensor with Multipoint Inspections can be configured for multiple regions of interest (ROIs) to ensure holes exist and were punched in the correct place. When set up for area inspection, the iVu will scan multiple points on the stamped part to verify the presence or absence of a feature or features of interest.

Thread Hole Detection

The WORLD-BEAM QS30's narrow laser beam can prevent these mistakes from happening it is necessary to verify, from a distance, that bolt threads have been cut into holes in a manifold.

Drilled Holes Inspection

This application uses an iVu Series sensor configured for an Area inspection. When holes are punched, the sensor evaluates all the holes to make sure that they are present and correctly sized. If any are not, the sensor sends a fail output to the line where the part is rejected.

Bearing Inspection

The solution involves using an iVu Series sensor configured for a Match inspection to ensure that all the bearings are present for each component that includes the bearing assembly. If the sensor detects one or more missing bearings, it sends a fail output to the line, and the component is rejected.

Engine Block Part-In-Place Detection

Banner’s LE550 laser sensor is ideal for part-in-place verification processes. It is reliable, and extremely accurate for small part-in-place verification from long distances. The LE550 measures for 3 mm thickness using the digital output, ensuring that the retaining clip is present and the engine block is in the correct place.

Automotive Welding Tip Inspection

The R55F high color resolution sensor checks whether the tips on a welder are within specifications, so the part being manufactured also is within specifications. In this harsh environment, the color contrast sensor uses glass fibers, for enhanced durability and heat resistance.

Part-in-Place Verification

The WORLD-BEAM QS18 adjustable field background suppression sensor is an excellent choice for this part-in-place application, requiring a three-inch scanning distance. With the combination of high-gain characteristics, sharp adjustable cutoff and a forgiving visible red light beam this sensor ensures longevity in this harsh environment.

Long-Range Inspection in Automotive Assembly

As vehicles move forward on an automotive assembly line, an L-GAGE LT7 time-of-flight laser sensor is directed inside the sun roof to verify that the car seat has been installed and is in the correct position.

Automotive Weld Nut Inspection

After a robot inserts multiple weld nuts in an automotive component, a worker places the part onto an inspection station equipped with two PresencePLUS P4 OMNI vision sensors. Improperly inserted weld nuts could be missing, upside down, or tipped to one side. The PresencePLUS P4 OMNI inspects to see that the weld nuts are present, correctly oriented and not leaning.The vision camera compensates for part-to-part movement and can inspect from a long distance.

Automotive Fuse Box Inspection

A PresencePLUS COLOR Pro vision sensor inspects color-coded fuses in a fuse box to verify that each fuse is in the correct location.

Automotive Duct Inspection

After a vacuum mass-airflow test of an automotive duct, a shuttle moves the PresencePLUS Pro into position above an open end of the duct. The PresencePLUS Pro verifies that a temperature sensor is still in place inside the duct and is undamaged.

Plastic Injection Short Shot Detection

A high-resolution PresencePLUS P4 OMNI 1.3 mounted above a production line inspects steering wheel components after they are molded. The P4 OMNI looks for areas with excess material or too little material.

Automotive Handle Color Inspection

A PresencePLUS P4 COLOR OMNI vision sensor detects interior door handles that are the wrong color for the vehicles being assembled. An on-axis light, attached with specialized brackets, provides even, diffused illumination to reduce glare.

Zero Defect Standard on Industrial Winder

A successful manufacturer of specialty industrial yarns makes fiberglass and glass thread products for applications in the automotive, aerospace, military and composite materials industries. To help maintain their high standards and minimize costly product returns, they established a goal of zero product defects. To meet this goal, the company needed an automated thread inspection system.

Part Color Inspection on a Vehicle Door Panel

An iVu Color Sensor identifies RGB values of individual pieces of trim on vehicle door panels and communicates this information over an industrial Ethernet connection to a PLC.

Automotive Seat Inspection

The Q5X verifies the presence of dark components on a dark background--as well as vehicle seats and components of varying colors.

Verifying Metal Sheets on a Stamping Press

The Q5X sensor verifies the presence and position of reflective targets in a harsh environment.

Reliably Detect Adhesive Tape on Pouch Batteries

When manufacturing pouch batteries for electric vehicles, adhesive tape material is used to complete the outer film packaging. The tape’s presence must be confirmed with optical-based sensors for quality assurance purposes. Keep reading to learn how the QCM50 color sensor solves this application.

Shopping Center Directs Vehicles to Available Parking

A large retail shopping center reduced vehicle congestion, customer aggravation and drive-offs using wireless sensors.

Electric Vehicle Detection at Charging Stations

Banner Engineering’s K50R radar sensor offers an ideal solution for electric vehicle detection at recharge stations. When cars park at a charging station, the radar sensor immediately detects the vehicle’s presence. If separate monitoring indicates that the car is not plugged into the charge station, a signal is sent to a central location, alerting authorities to ticket or remove the vehicle if necessary.

Bank Drive-Thru Automobile Detection

Banner Engineering's K50R short-range radar sensor can be used to detect vehicles at bank teller drive-thru windows. It is designed to operate in any outdoor weather conditions.

Detecting Parking Spot Availability

Banner Engineering's weather-resistant K50R short-range radar sensors can be placed above parking spaces in a large, multi-level parking structure to monitor parking availability and help drivers to find open parking spaces more easily.

Detecting Parts Ejected from Die

In the manufacturer's facility, operators manually insert and remove metal parts from the die press. When complete, the parts are sent into a bin via a metal chute. In order to prevent die crash (having double parts in the press at once) the customer needed a sensor that could detect various parts on the chute and send a signal to the control system, indicating that the press is free and allowing the operator to perform another stroke. The solution needed to be installed without cutting slots in the chute sides or mounting sensors at the end of the chute, which could create catch points for traveling parts.

Communication in a Busy Manufacturing Site

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.

Window Tint Verification

Banner’s DF-G1 light receiver sensor differentiates between windows with or without tint based on how much external light passes through the glass. The DF-G1 self-contained device has a simple push button set-up for easy adjustment along the conveyor. An intuitive user display allows for immediate sensor feedback.

Light Receiver Detects Broad Spectrum of Lights

Banner’s DF-G1 fiber optic light receiver is a unique, cost-effective product that is designed to be placed directly in test equipment to ensure lights are functioning correctly. With the same intuitive dual display and programming interface as other DF-G1 models, the light receiver can be integrated and interfaced with assembly and test equipment control systems for pass/fail inspection.

Optical Touch Button and Emergency-Stop Operator Station

With the all-in-one unit, the emergency stop pushbutton combined with an OTB provides a simplified operator station for manufacturing lines that does not require wiring or additional enclosures. Banner’s 30 mm mount E-Stop buttons work well in this type of application. Their illuminated base turns from yellow to flashing red when actuated, making them compliant with emergency stop requirements. The proximity of the emergency stop button to the OTB means workers can quickly and easily actuate

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.

Rotating Equipment Monitoring

In a number of automotive manufacturing processes, rotary tables are used to index parts into various automatic and manual work stations. In many cases, it is necessary to use sensors to verify that parts are present, properly placed, or correctly processed before indexing. Historically, the solution of using slip rings to allow sensor power and signals to be hardwired to the control system has often proven to be costly and unreliable. An alternative solution that allows more sensor signals to be processed while increasing the reliability is needed.

Die Protection in Tire Manufacturing

The dies in tire presses suffer costly damage if the press tries to stamp the tread into an unstamped, or green, tire of the wrong size. To direct each tire to the correct press, Banner’s PresencePLUS P4 BCR 1.3 vision sensors sort green tires based on identifying information in the bar code printed on a label on the tire’s bead. In this application, the green tires moving on a conveyor pass below a fixture on which six BCR 1.3 vision sensors are mounted.

Wireless Reduces Downtime

A producer of stainless steel and special alloys supplies billets, blooms and ingots to the metal casting industry. During production, articulating robots are used to handle magnesium billets. Proximity switches located on the end effectors of the robots communicate status information from the grippers to a control panel. Robotic cables had been used to connect the proximity switches to the control panel. Environmental challenges and the motion of the robot compromised the integrity of the cables. Breaks were quite frequent and production had to be halted for repair and replacement, pushing up costs and driving down productivity.

Bypass Capability on a Robotic Work Cell

Using a 2 or 3-position OS80 key operated selector switch, the operator can bring the robot to a controlled stop, enter the cell, and then quickly resume operations once work in the cell is complete.

All Automotive Solutions