Application Notes

Condition Monitoring: Predictive & Preventative Maintenance

Identify machine problems before they cause serious damage or unplanned downtime and alert staff of changes in condition via text message or email as well as provide at-a-glance local indication of machine status.

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.

Illuminated Forklift Guidance

The WLS27 Pro with discrete control and configured by Banner’s Pro Editor software is one of two new models of the WLS27 Pro series strip light. It now includes programmable RGBW LEDs for use in illumination, indication and inspection applications. Learn how the configurable WS27 Pro provided forklift guidance for warehouse operators.

Indicating Operational Status of Boiler Room

When one of the boilers in the boiler room of an apartment building started exhibiting issues, the building manager needed to find a long-term solution that could identify maintenance issues quickly and accurately.

Status Indication of Skid Steer

Find out how a local construction company worked with Banner Engineering to find a solution that alerted workers to the location and status of a skid steer.

Small Motor Condition Monitoring & Predictive Maintenance

Condition monitoring with Snap Signal

Wired & Wireless Tech Combo for Optimal Vibration Monitoring

Snap Signal offers the flexibility to monitor vibration for large numbers of motors with one easy-to-install soution.

Leading Edge Detection

Sensors detect the leading edge of pallets, polybags, blister packs, envelopes, tubes, and a wide range of difficult to detect targets.

Date/Lot Code Presence or Absence Detection

An SLM series slot sensor and an iVu Series vision sensor are used to detect bottles passing on the line and to verify that date/lot codes have been correctly printed onto the bottles.

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.

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

Measure Throughput and OEE on a Case Sealer

Maximize throughput and reduce downtime by harnessing existing data from your equipment.

Condition Monitoring of Dust Collection System

Snap Signal converters provide monitoring data so users can spot small performance changes. This solution indicates problems that can be fixed early and fully with preventive maintenance.

Monitor Leaks in Your Critical Applications

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

Monitor Tank Level Remotely in a Snap

Monitor sensors and devices with ease -- new or existing -- and efficiently manage your inventory.

Discrete Sensors to the Cloud

Snap Signal products utilized existing legacy sensors that were already installed to offer valuable insights on process states and error conditions. Product managers were able to monitor machine performance and help optimize throughput via sensor data sent to Banner Cloud Data Services (CDS).

Increase Productivity on an Injection Molding Machine

Make your legacy injection molding machine smart – Give it Industry 4.0 capability – with Snap Signal.

Bring IIoT to your Industrial Equipment with Ease

Snap Signal makes it easy to incorporate industrial internet of things (IIoT) technology to your equipment.

Monitoring Motor and Bearing Temperatures in Hazardous Areas

Banner’s DX99 Nodes offer solutions for monitoring the temperature of motor bearings using thermocouples or RTDs. Because these are low power sensors and radios, a battery life of up to three years is possible. The Node sends temperature data wirelessly back to a central control location for logging and analysis. When the bearing temperature rises unexpectedly, maintenance can be scheduled before any motors burn out or equipment is damaged. It is likely this temperature data would not be monit

Monitor Roll Diameter and Increase Machine Uptime

Your machines need a constant supply of materials to keep production going. Knowing when they’re running low is critical. Snap Signal provides this data and makes it available for viewing anywhere it’s needed.

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.

Inbound and Outbound Status Indication at Loading Dock

In a recent material handling application, facility managers needed to find a solution that would alert them to the status of trailer capacity at loading dock doors in real-time.

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.

Increasing Productivity with Pick-to-Light System

Learn how In the Ditch™, an Idaho-based manufacturer of award-winning products for the towing industry, was able to make substantial improvements to the efficiency and accuracy of their picking processes by implementing a complete pick-to-light system from Banner Engineering.

Illuminate Web Inspection Stations with Rapid-Install LEDs

Hermes Abrasives requested lighting to improve inspection capabilities of abrasive products.

Call for Parts, Service, or Pallet Pickup

Increase production efficiency by developing a wireless call-for-parts, service, and Andon system that allows for up to 35 work stations to call out to 12 forklifts/Hi-Los using the EZ-Light K70 Touch to wireless Direct Select operator interface.

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.

Sensors to Measure Movement Range

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

Monitor Vibration: Prevent Costly Downtime in Boiler Room

Learn how the installation of Banner wireless vibration sensors and data from the DXM wireless gateway prevented unplanned downtime in this application.

Tracking Package Location through Conveyor Roller Gaps

• Precise location detection • High-speed conveyor • Customer specific product

Predictive Maintenance for Crane Motors and Gearboxes

Wireless products enable predictive maintenance in the port industry. Motors and gearboxes on cranes are prone to high vibration and temperature which can cause them to degrade. Predictive maintenance allows employees to interfere and solve problems before they completely fail and cause unplanned downtime and lost profit.

Monitor Fill Level of Liquid in Mobile Drum

The K50U wireless ultrasonic sensor was designed specifically as a non-contact level monitoring solution. Monitoring the levels of epoxy in drums during refill alerts staff of potential overflows before they become a problem.

Warehouse Vehicle Detection with Indication

Vehicle detection at loading docks is complicated because sensing solutions are exposed to the elements and need to recognize a wide variety of surfaces. Rugged ultrasonic sensors work well to accurately detect the surfaces of delivery vehicles regardless of the material. Pairing with bright LED indication creates unmistakable operator guidance.

Predictive Maintenance of Rotating Parts on Conveyor

Wireless monitoring of rotating parts on coal conveyors throughout a large port allows operators to utilize predictive maintenance to prevent failure and save money while reducing downtime.

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.

Greenhouse Temperature and Humidity Monitoring

A Sure Cross FlexPower™ Node with internal battery directly connected to a temperature and humidity sensor can provide these measurements without costly conduit or cabling, eliminating the need to manually collect data from multiple sensor locations. IP67 electronics and a variety of filter options make this product suited for the wide temperature and humidity ranges encountered in a greenhouse.

Hot Glue Detection

T-GAGE M18T Series Temperature Sensors are passive, non-contacting, temperature-based devices designed to detect objects that are hotter or colder than the ambient condition, and then activate an output. In this application, the T-GAGE temperature sensor will detect the presence or absence of hot glue on the flaps of the package. If the hot glue is present, the process will continue and the package will be sealed. If it’s absent, the output will trigger a process to apply the hot glue.

Hot Glue Detection on a Package

Banner’s T-GAGE M18T temperature sensor is ideal for hot glue verification because it detects the infrared energy an object emits to determine its temperature, sensing from 0⁰C to 300⁰C. In this application, the T-GAGE M18T temperature sensor detects the presence or absence of hot glue on the flaps. If hot glue is present, the package will continue down the manufacturing line;if it is missing, the output will trigger a pusher arm to kick the carton off the conveyor into a bin.

Controlling Temperature and Humidity for a Cabinet Maker

A large cabinet maker needs to monitor and control the temperature and humidity throughout many rooms in a large production facility. Manual environmental readings of the entire plant were conducted periodically throughout the week. These manual readings only provided a snapshot of information and gathering the data took more than three hours. The customer did not have real-time, accurate information that could be used to control the plant environment. Manually collecting this information and controlling the fan system was timeconsuming and resulted in errors that damaged wood in storage, work in progress, and finished cabinets.

Machine Status Indication in Automated Clinical Laboratories

Clinical labs need to process samples quickly to keep throughput high and any lag during testing procedures would disrupt workflow. LED lightings, such as the K50L2, works as machine status indication so that the lab operators can process fix errors, handle samples, and collect results in a timely manner.

Machine Monitoring/Overall Equipment Effectiveness

• Expand available data beyond local indication • Gather information necessary to react quickly • Drive efficiency improvements based on data previously unavailable

Environmental Monitoring inside a Machine Control Panel

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

Monitor Production I/O for Better Equipment Effectiveness

Monitoring production inputs and outputs provides machine operators and managers with critical data about their processes and equipment and can help them identify and resolve problems on the production line more quickly.

Illumination and Indication for PCB Assembly

Placing WLS27 Multicolor LED Strip Lights with EZ-STATUS above PCB assembly machines provides area lighting and status indication with one rugged and versatile light. Any changes in machine status cause the WLS27 to switch from illumination to indication and cover the entire machine with the corresponding color. This type of indication allows operators to focus on the task at hand without missing changes in machine status.

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.

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.

Thermal Remediation Temperature Measurement

The EPA has placed restrictions on the use of many fumigants citing a correlation between their use and ozone depletion. As an alternative, a large-scale flour mill performs three to four thermal remediations per year to eradicate flour beetles. The temperature inside the mill is brought up to 122° F (50° C). This is done gradually to minimize equipment and building strain caused by heat expansion.

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.

Reliable Detection of Transparent Bottles on Conveyor

A machinery company needed a sensor able to consistently detect clear PET bottles at multiple points.

Detecting Various Registration Marks

Hamer, LLC is a Minnesota-based manufacturer of automated packaging equipment for a wide variety of applications and world-wide customers. From pet food to pellet fuels, Hamer machinery packages products in a variety of weights and sizes at speeds up to 60 bags per minute. A vital component of Hamer’s equipment is registration mark sensing—the ability to detect marks on packaging as it passes at high speeds. When a mark is detected, the equipment cuts the packaging at the designated location, eliminating waste and ensuring each bag is consistent.

Simplifying Safety Feature Management

Algus Packaging Inc. is a leader in the heat seal and thermoform packaging industry. They design, develop and manufacture high-performance sealing machines, thermoformed packaging and offer full service contract packaging. The machinery and services offered by Algus provide their customers with the ability to change and grow as business needs dictate, now and in the future.

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.

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.

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.

LEDs Replace Fluorescent Fixtures in Machine Enclosures

• Bright illumination inside weld machine • Comparable in cost to fluorescent lights • Uniform, even lighting

Efficient LED Light Bars Reduce Build Times and Expenses

The company wanted a cost effective lighting solution that would offer brilliant illumination on multiple work stations on large product testing machinery.

Accurately Measuring Bakery Ingredients

Baking is a mixture of creativity, precision and attention to detail. The Wilkinson Baking Company has added technical innovation to the mix. The Wilkinson Bread Bakery is a compact, completely self-contained and fully automated bread bakery. This unique machine combines technology with tradition to transform simple raw ingredients into bakery fresh bread at 40 loaves an hour.

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.

Preventing Shipping Errors at a Large Distribution Center

The customer was looking for a single-output solution that senses packages quickly, is easy to install and maintain, and was affordable enough to buy in bulk quantities if needed.

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.

Frost Protection and Soil Moisture Control in Cranberry Bogs

Soil moisture and air temperature sensing ranges are typically under a mile, but the Site Survey tested the signal out to two miles. With the MultiHop Radio and its antenna installed very low to the ground, the Master Radio was installed with a large omnidirectional antenna to maximize the communication range.

Predictive Maintenance for Motors

SureCross devices can monitor temperature, vibration, and pressure. A mobile FlexPower Node equipped with up to three thermocouples monitors critical bearing temperature and sends the data to a Gateway for logging. With this information, maintenance personnel can service the machine based on performance indicators and minimize down time.

Local Status Indication

Local indication solutions provide clear, highly visible status alerts to both operators and plant managers in their normal sightlines.

Measuring Wear Patterns on Conveyor Belts

Elevators, escalators and moving sidewalks are major investments in any facility’s infrastructure. This equipment is expected to operate safely and reliably for many years and with minimal downtime for maintenance. To meet these expectations, a large-scale manufacturer of vertical and conveyor transport equipment performs rigorous tests on all system components. The data that is collected helps the company estimate component life expectancy and plan service schedules.

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.

Consistent Dough Height Measurement

The dough for one of the company’s many popular breakfast cereals must fall within specific height parameters to ensure that it will have the perfect flake. Dough that is too thick will emerge from baking stiff and heavy. Dough that is too thin will crumble easily. This impacts the quality, taste and texture of the final product as well as product weight and packaging. Any product that does not meet the rigorous quality standards of the company will not be shipped or sold on the consumer market.

Measuring Turnout Time During Emergencies

Sensor solutions to add vehicle detection to Fire Department dispatch and reporting systems.

Radar Based Collision Avoidance in Mining Environments

Sensor solution for blind spot object detection for large vehicles, alerting operators with time to respond.

Accurate Label Inspection

The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

Combined Inspections Used to Meet Quality Standards

Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.

LED Lights Used To Inspect Liquid Pharmaceuticals

One global provider of healthcare products had been using vision machines to detect particulates in their liquid pharmaceuticals. When the machines were no longer able to detect contaminants to the required percentage level, the company began using human visual inspections. Since many of the particulates are extremely minute, the company needed to install bright and highly uniform illumination in their work stations so operators could effectively verify the quality of products.

Hot Part Detection in Food Preparation

To ensure that a griddle is on, non-contact T-GAGE M18T temperature sensors are aimed at the cooking surface to detect that the surface is hotter than the surrounding air. If the waffle iron is hot, the batter will be poured in and the process will continue. If it is not hot enough, the T-GAGE temperature sensor output won't trigger the batter release mechanism allowing the iron additional time to heat.

Indicate Robot Positioning

Learn now a manufacturing company used a WLS15 Pro to improve safety in their warehouse.

Simple Workstation Control

With its low-profile and sleek design, the LC15T is an easy-to-use interface for controlling a wide range of DC devices. The LC15T effectively communicates status to users with green, blue, and red colors to indicate different device states.

Remote Monitoring

Remote monitoring enables increased visibility into the performance and efficiency of machines, processes, and people.

Tank Level Monitoring

Remotely monitoring tank level can help improve efficiencies and increase productivity and profitability.

Vibration Monitoring for Predictive Maintenance

Banner’s wireless vibration and temperature sensor measures RMS velocity, in inches per second or millimeters per second, and temperature. Mounting it as close as possible to the bearings enables you to monitor the machine’s health by detecting increases in vibration and temperature. It is easy to mount using the standard bracket, the magnetic bracket or two sided thermal transfer mounting tape.

Motor Condition Monitoring for Predictive Maintenance

FlexPower Nodes equipped with thermocouple or RTD sensors were mounted near the monitored motors. The sensor data is sent to a Gateway installed in a central control location. The temperature set point can be established to meet the applications requirements and then provide a discrete output from the Gateway. When predetermined temperature levels are detected, the red light of a stack light connected to a Gateway lights up, alerting personnel that maintenance is required.

Predictive Maintenance and Condition Monitoring

Predictive maintenance enables users to more accurately anticipate when machine maintenance will be needed based on real-time data from the machines themselves.

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.

Paint Tunnel Inspection in Motor Vehicle Manufacturing

Inspection with high quality illumination, identifies vehicles needing additional work to ensure the highest quality paint finish.

Increase Drive-Thru Business with Wireless Vehicle Detection

Wireless vehicle detection at a quick serve restaurant drive-thru.

Pick-to-Light Accelerates Final Assembly and Order Fulfillment

Learn how a golf equipment manufacturer recently used PTL110 pick-to-light devices to simplify and accelerate their final product assembly and order fulfillment processes.

High Speed Package Profiling with Laser Sensors

3 Apr 2019

A laser measurement solution enables high-speed package sorting in order fulfillment applications and helps drives failure rates down—ultimately saving costs and maximizing profits.

Reading Multiple 1D and 2D Barcodes

Barcode position can change with the location of each box on a conveyor and the height of the boxes can vary. An ABR 7000 barcode reader decodes multiple 1D and 2D barcodes over a large area in a single inspection, regardless of position or orientation.

Tracking Products through Packaging

Barcodes used to track packaged produce through the supply chain contain important product information that must be verified at multiple points during packaging. An ABR 3000 barcode reader ensures that the barcode on each package is present and correct.

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.

Easy-to-See Status Indication in Close Proximity to Staff

To optimize efficiency and output, the progress of multiple FOUPs in single wafer deposition machine must be closely monitored. Staff work in close proximity to these machines and prolonged exposure to bright light from tower lights can cause eye strain, leading to physical and mental fatigue. Keep reading to learn how TL30 Basic tower lights solve this application.

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.

Detecting Integrated Circuit Chip Presence and Orientation

A precise measurement solution is required to ensure that integrated circuit (IC) chips are present and oriented correctly in nests. Learn how the LM laser measurement 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.

Overall Equipment Effectiveness (OEE)

Remote monitoring capabilities provide data for OEE calculations, making it easier for manufacturers to identify and remedy causes of waste within their facilities.

Factory Communication

IIoT technologies enable better communication throughout the factory and streamline processes for machines and people alike.

IO-Link

There are many advantages of IO-Link including reduced wiring, increased data availability, remote monitoring, simple device replacement, and advanced diagnostics.

Temperature and Humidity Monitoring Solution Guide

Using K50U ultrasonic sensors and Q45U wireless nodes paired to a DXM100 wireless controller, we can develop a wireless monitoring system for multiple tank level measurements that is easy to set up, interpret the results, and monitor locally through a cloud-based system.

Valve Temperature Monitoring at a Steam Power Plant

To allow for quicker, more frequent, and more efficient scanning of target valve population tailpipe temperatures, a series of FlexPower Thermocouple Nodes and FlexPower Battery Supply Modules are installed. Temperature measurements of the valves and pipes are measured and wirelessly transmitted to a DXM100 Wireless Controller mounted in a central location. The DXM100 gathers the data and transfers the data to a SCADA system that monitors and graphically displays the temperature data.

Monitoring Rotating Kiln Temperatures

The SureCross Wireless Sensor Network eliminates complexities associated with data acquisition from rotating and moving machinery such as a rotating kiln. Crucial temperature data is acquired using a thermocouple or RTD and transmitted from the FlexPower Nodes to a remote Gateway in the plant's control center. Data is always concentrated in the same location for processing or analysis, and manual data collection and physical risks to personnel are eliminated. Temperature data is logged and anal

Refrigeration System Monitoring with a Wireless Network

A resistance temperature detector senses the temperature of a walk-in cooler and sends the data to a SureCross FlexPower Node. The Node in turn sends that data to a Gateway, which issues an alarm to management if the temperature exceeds acceptable limits. The DX80 FlexPower Nodes have a IP67 rating for rugged environments and work well in the cold.

Monitoring Temperature During Composting

Manual data collection is eliminated using a SureCross FlexPower™ Node equipped with two thermocouples to automatically monitor the temperature at two depths within a compost windrow or stack.

Monitoring Rotating Equipment

Taking measurements on rotating equipment, such as a kiln or rotary table, usually requires a complex and expensive system of cabling. Even taking precautions and using specialized equipment doesn’t eliminate cable tangles and breaks. The SureCross Wireless Network eliminates complexities associated with data acquisition from rotating and moving machinery such as a rotating kiln. Crucial temperature data is acquired using a thermocouple and transmitted from the FlexPowered SureCross Nodes to a

Monitoring Environmental Conditions

A semiconductor fab needs to monitor temperature, relative humidity, and oxygen levels at multiple points within their processing plant, along a 2 kilometer long process piping system. They require a solution that monitors temperature, relative humidity, and oxygen levels, provides a location for the monitoring points, and collects all data to a central point and interfaces with their SCADA system. The solution needs to create an efficient, safe work environment for all employees. With over 2 kilometers of underground tunnel piping systems, installing cable to each monitoring location is cost prohibitive.

Restocking Assembly Stations for a Continuous Workflow

Restock assembly stations before components run out without overstocking.

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.

Wireless Pick-to-Light System for Mobile Assembly Stations

Minimize production errors by providing clear guidance for assembly.

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.

Industrial Refrigeration System Pressure Level Monitoring

Performance Series all-in-one wireless pressure sensors make it easy to monitor pressure levels in large and complex systems from any network-enabled location.

Vibration Monitoring a Main Air Handler [Success Story]

When the main air handling unit in a boiler room of a local corporate building was exhibiting potential issues, workers wanted to find a long-term solution so that they could identify maintenance issues with accuracy and in a timely manner.

Wireless PPM Kits

Challenge: Identify and correct the source of reduced output in one of multiple production lines. A water bottling operation had five steps in its bottling process: Cleaning, Filling, Capping, Labeling, and Packaging. One of the plant’s production lines had a recurring problem of lower output than the other lines. The production manager wanted to identify the step, causing bottling constraints and quantify losses in the underperforming line in order to determine how to bring output up to that of the other lines. The bottling machine in question was older and had no way to monitor throughput.

Pressure Sensor Data for Immediate Insights

Snap Signal products connect sensors of various types and convert their signals to a unified serial protocol, making it possible to monitor production facility conditions in real-time, including system pressure.

Temperature Data to the Cloud

Knowing when your system temperature is too high or too low allows you to optimize your application for optimal performance.

Clear and Reflective Targets

Detecting clear and reflective objects are some of the most challenging sensor applications. Light can burn through a target or be reflected away erratically, making accurate detection difficult.

Dark and Low Contrast Targets

Dark objects are difficult to detect since they reflect very little light back to the sensor. In addition, black on black targets (low contrast between target and background) are especially challenging.

Multicolor Packaging

In packaging, targets often contain vibrant, multicolored graphics of varying reflectivity. Such varied targets can be difficult to detect reliably, especially when there are many color transitions.

High Speed Applications

Many applications, such as registration mark detection and high-speed part counting, require sensors with response speeds fast enough to reliably detect fast moving targets.

IO-Link

There are many advantages of an IO-Link system including reduced wiring, increased data availability, remote monitoring, simple device replacement, and advanced diagnostics.

Sanitary Detection of Clear Plastic Food Containers

Clear, thermoformed plastic containers, trays and clamshells are used to package a wide variety of products. Packagers must be able to detect the leading edge.

Detecting Bottles in Washdown: Glass & PET Plastic

Detect clear glass and PET plastic bottles with various shapes and sizes. Washdown environment, IP69K ratings.

In-Line Accumulation on Single Filer

The Q5X laser sensor reliably detects when the staging area is clear of bottles and the system is ready for the next layer of containers, despite the transparency of the bottles and unstable signal.

Detecting PET Bottles to Regulate Product Flow

Sensor solutions to detect translucent bottles in a range of shapes, sizes, colors and contours in a high-speed air conveyance system, identifying gaps.

Counting Multicolored Reflective Packages on a Conveyor

Sensor solutions to verify packaging and count on conveyor. Foil and film packaging such as tea bags, multiple colors on packaging material.

Glass Vial Detection: Hygienic Sensors in Harsh Chemicals

Sensor solutions to detect clear vials in pharmaceutical and medical manufacturing where a hygenic sensor is needed in a harsh chemical washdown environment.

Clear Glass Jar Detection for Food and Beverage Splash Zone

Sensor solutions to detect clear glass jars to be filled with food in a strict sanitary environment where frequent, high-pressure washdowns and IP69K ratings.

Detecting Clear Bottles to Trigger Shrink Sleeve Labeler

Sensor solutions to detect bottle types with varying frequent in product changovers. High-speed labeler processing 800 bottles per minute, high temps.

Detecting Transparent Bottles in a Washdown Environment

Sensor solutions to detect accumulations to regulate line pressure where bottles vary in size, shape, color, and translucence and there is not a reflector.

Detecting Reflective Packages on a Conveyor

Sensor solutions to detect reflective food wrappers such as Mylar with conveyor belt presence verification, utilizing foreground suppression.

Controlling Line Pressure of Clear Food Trays at Denester

Using a sensor in clear object sensing mode to ensure proper staging of plastic trays during denesting process.

Accurate Counting of Transparent Pharmaceutical Bottles

Sensor solutions to count translucent and reflective glass vials in high-speed processes requiring quick response times and challenging light conditions.

Monitoring Flow of Transparent Plastic Bottles on a Conveyor

Sensor solutions to monitor a conveyor to ensure there are no stuck bottles when bottles are clear plastic in a large sensing area.

Counting Transparent Plastic Containers on a Conveyor

Sensor solutions to count containers that are made of clear plastic when containers are various shapes and have ridges.

Counting Reflective Rings

Sensor solutions to count rings on a conveyor belt where the rings have a very reflective surface and a cylindrical shape.

Seal and Perforation Detection on Translucent Poly Bags

Sensor solutions to detect perforations on continuous web of translucent plastic bags where high-speed equipment is used and a large-volume of material process.

Detecting Clear Pharmaceutical Vials Filled With Liquid

Sensor solutions to detect glass vials filled with transparent liquid in an aseptic, stainless steel environment with rounded bottles.

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.

Transparent Glass Bottle, Vial, or Plate Detection

Sensor solutions to recognize clear glass vials and bottles in high-speed application with precise leading edge detection.

Profiling Clear Glass Plates and Detecting Broken Edges

Sensor solutions to detect a low contrast edges of glass on conveyor in a clean industrial environment where equipment is regularly exposed to high temperatures

Detecting and Indicating the Presence of a Tipped Bottle

Sensor solutions to detect translucent bottles filled with clear liquid with a long bottling line with numerous areas to monitor.

Color Sensor Automates Sorting of Clear and Tinted Bottles

Sensor solutions to detect plastic bottles varying in color and translucence where a high-speed system requires fast response times. Accurate sorting.

Detection of Clear Liquids in Transparent Packaging

Sensor solutions to detect I.V. bags, glass vials, syringes and pharmaceutical packaging. Fill level inspections ensure product content amounts are accurate.

Detecting Tipped-Over Bottles on a High-Speed Bottling Line

Detect translucent bottles varying by size, shape, color, and faceting. Large scale system of monitoring in multiple locations, quick clearance of tipped bottle.

Detecting Shiny, Unfinished Cans

Sensor solutions to detect small installation areas with multiple deployments on the line. Accurate detection of shiny cans supports smooth product flow.

Clear Container Detection in a Clean-in-Place Rotary Filler

Sensor solutions to detect bottle types vary in size, shape, color, translucence, and material. Equipment is regularly exposed to harsh washdown.

Hygienic Sensor Detects Variety of Bottle Types on a Rinser

Sensor solutions to detect bottle types vary by size, shape, color, contours, and translucence on a rinser where equipment is regularly exposed to washdowns.

Clear Tray Detection at Hopper Food Storage Units

Learn how the Q4X detects clear plastic trays at hopper and filling station in the food industry.

High-Speed Registration Mark Detection

Banner’s Q3X versatile, rugged laser contrast sensor is ideal for detecting registration marks. With a range up to 300 mm, the Q3X has a tight laser spot able to detect a small white registration mark reliably. When the Q3X detects the white registration mark, the intensity readout increases and a discrete output is triggered, indicating the white registration mark is present and it is the correct package going down the line.

Detecting Registration Marks on Labels

Banner’s R58 high-speed, low-contrast expert registration sensor detects subtle registration marks on the labels as they pass at high speed—ensuring the label is cut at precisely the right moment for correct label placement. To accommodate frequent changeovers, the sensor is designed with LED color options—which automatically change depending which color best optimizes contrast.

Splice Detection in a Paper Roll

Banner’s R58 Expert registration mark high color resolution sensor is a high-performing sensor with an ultra fast 10 kHz switching frequency that quickly detects splices and other defects that are otherwise hard to detect. The high sensitivity of the R58 Expert detects the inconspicuous splice in a roll of paper to ensure the printer skips over the splice during the press process.

Toothpaste Registration Mark Verification

As empty tubes go down the manufacturing line, a visible light sensor can verify a toothpaste tube’s registration mark before being filled and sealed. Banner’s high-speed R58 visible light color contrast sensor is an extremely powerful sensor for registration mark applications and can easily read marks on high-gloss and low-contrast surfaces, detecting contrasts as low as two percent over a wide range of colors.

Tube Positioning Using a Registration Mark

Banner’s R58 Expert registration mark color contrast sensor is a high-performing sensor with an ultra fast 10 kHz switching frequency that quickly detects registration marks, which is ideal for tube positioning applications. Even with a high-gloss surface or a low-contrast situation, the R58 Expert can easily detect the registration mark on a filled tube to determine how it should be oriented.

Registration Mark Detection on a Labeler

Banner Engineering’s R58B Expert registration mark sensor confirms the registration mark’s position on the web. This allows the machine to make minor infeed adjustments to ensure the cut is properly placed and all labels are consistent and complete. If the labels are incorrectly cut they need to be removed from the bottling line creating costly downtime and waste. A quick and easy-to-use sensor is needed to dramatically improve throughput.

Smart, Scalable Safety Control

Industrial safety controllers provide an interface between safety devices and the machines and processes those devices monitor for an easy-to-use safety control solution.

Point of Operation

The point of operation on a machine is where the work is performed. Because workers are in close proximity to pinch points, safety is critical.

Perimeter and Access Guarding

Perimeter guarding applications require guarding on multiple sides of the machine. Meanwhile, access guarding protects an access point into the hazardous area.

Safe Start and Stop

Operators must be able to safely start (initiate) machine processes as well as safely stop them in an emergency.

Guarding Conveyor Entry on Palletizer Machines

Safeguarding palletizer machines present many challenges to keep personnel safe and maintain efficient production. The new SGS Safety Grid with muting arm bar kit protects the dangerous robotic machinery while allowing boxes to pass through the Grids without stopping production. The muting arms can recognize if anything other than a box passes through the Grids and will trigger a machine stop on the palletizer.

Safety at Palletizer Station with Sticky Liquids Present

Safeguarding palletizer machines can be difficult because bottles are under a lot of pressure and can contain corrosive liquids such as soda or juice. Hygienic enclosures protect light curtains from corrosive liquids, meet sanitary requirements, and do not affect the performance of the sensor.

Safety Measures for Meat Slicing Machine in Harsh Conditions

Safety light screens on a meat slicer protect operators from sharp blades while in operation. The environment is harsh and frequently exposed to chemical washdowns. The EZ-SCREEN LS with hygienic enclosure keeps personnel safe while preventing water and chemical damage to the light screen.

Small Assembly Station Protection with Light Curtains

EZ-SCREEN LS safety light curtains have no DIP switches, feature end-to-end sensing, and can be easily installed with automatic configuration. The use of side mount brackets creates a quick and simple installation with adjustments made from the front side of the EZ-SCREEN LS arrays, saving time during setup. Maximizing machine uptime and reducing repair and replacement expenses helps companies remain competitive.

Dual-operator Robotic Work Station

Safeguarding multiple access points to a hazard with its automatic cascade feature allows up to four light screen sets, of any size and resolution, to be connected in a series saving panel space.

Depalletizer Guarding with Muting

LS light curtains are intuitive, easy-to-use safety devices used for machine safeguarding. They are built to withstand challenges commonly found in manufacturing and packaging environments. LS-S models require no PC software, DIP switches, or other devices for quick, easy configuration. Highly visible alignment indicators and intuitive diagnostics simplify setup, facilitate troubleshooting, and minimize system downtime.

Robotic Palletizer Safeguarding

Banner’s XS26-2 is a flexible, easy-to-use safety controller with an intuitive programming environment, with the capacity to handle current machine processes and the flexibility to add up to eight I/O expansion modules as machine automation grows or changes. A broad spectrum of safety devices are supported, allowing for complex applications to be configured and downloaded to the controller in a minimal amount of time for efficient machine commissioning.

Scalable Safety Control for Large Assembly Processes

Banner’s XS26-2 expandable safety controller is a scalable safety solution that can be tailored for a wide variety of machines, including large scale machines with multiple processes. With the ability to add up to eight I/O expansion modules, the XS26-2 has the capacity to adapt to larger footprint machines with multiple hazards and access points. Several preconfigured safety function and logic blocks are available in the intuitive programming software.

Safeguarding a Robotic Palletizer

Banner’s SC26-2 is a flexible, easy-to-use safety controller with an intuitive programming environment. The programmable safety controller can manage all of the safety devices with one module. The SC26-2 communicates the status of safety devices via Ethernet IP and controls a tower light for visual indication of safety device statuses. The base controller allows eight of the 26 inputs to be configured as outputs for efficient terminal utilization.

End-to-End Safety Sensing

The solution requires the sensor to mount snugly within a machine opening, with continual end-to-end sensing that leaves no gaps. This enables the light screen to be located a minimum distance from the machine hazard point, using minimal floor space (which reduces the reach for the operator), and eliminating snag and aesthetic issues. At 28 mm x 26 mm (1.1" x 1"), Banner's EZ-SCREEN LP safety light screen is incredibly compact and can mount in tight spaces.

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).

Lower-Risk Machine Guarding: Carousel

The Type 2 EZ-SCREEN safety light screen protects hands and fingers from being bumped, bruised, or pinched by the moving parts of a carousel.

Lower-Risk Machine Guarding: Chip Shooter

The Type 2 EZ-SCREEN safety light screen guards the opening to a chip shooter, which has moving parts that can cause painful but usually temporary injuries.

Single-Point Access Guarding

Two angled mirrors bounce the beam from the emitter to the receiver of the EZ-SCREEN safety light screen Point, so one Point does the work of two.

L-Configured Guarding

At both open sides of a robotic work cell, a pair of EZ-SCREEN safety light screens are linked—or cascaded—in an L-shaped configuration to guard the access point both vertically (reducing separation distance) and horizontally (providing continual sensing). Up to four pairs of EZ-SCREEN light screens can be connected.

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.

Perimeter Guarding with Mirrors

To guard the perimeter of a tube bender work cell, two free-standing corner mirrors are set up to reflect the sensing field from the emitter, around the perimeter’s corners, to the receiver. Using corner mirrors is an economical way to make use of the range of an EZ-SCREEN safety light screen by guarding multiple sides of an area with one emitter/receiver pair.

Safeguarding a Single-Station Robot Weld Cell

The Banner AG4 Safety Laser Scanner is placed at the base of the hazardous area and “looks out” at the open area. It is programmed via a PC with interface software to guard the area between the physical barriers (the protective zone) and outside the barriers (the warning zone). If the operator or other personnel approach the hazardous area during robot operation, a signal is sent to alert the person that the warning zone has been entered; the robot continues operation during this time.

Robotic Guarding in Work Area without Limiting Access

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.

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.

Machine Safeguarding in an ESD-Sensitive Environment

In this application, machine operators require access to the wafer carrier station. The EZ-SCREEN ESD safety light curtain system is configured to safeguard the process and operator using emitters, receivers and mirrors to enclose three sides of the station. Safety light curtains allow quicker, easier access than physical barriers while preventing machine movement if the operator reaches into the hazardous zone.

Heat Stake Machine Safeguarding

In this example, two sides of a heat stake machine require guarding because of separate operator load and unload stations. On each side of the station, two safety light screens protect workers; one with a 48" vertical light screen for area guarding and one with a 12" inclined light screen to guard the point of operation where the tool is loaded and unloaded.

Safety Light Screens Guard Operators from Sweep Bar

The EZ-Screen LPs Type 4 Safety Light screens guard the operators of a depalletizer from the motion of the sweep bar. To guard individuals from the sweep bar, a 14mm resolution between beams prevents access and injury. If an individual or item breaks the beams of the EZ-Screen, the sweeping motion will stop to prevent harm. The low-profile design of the light curtains allows for easy installation along a machine and does not require a PC or additional equipment for setup.

Safeguarding of a Power Press

Banner Engineering’s EZ-SCREEN LS is extremely robust with heavy duty extruded aluminum IP65/67 rated housing, metal endcaps and a recessed window to protect it from collisions related to stock removal and incidental impact.

Depalletizer Guarding with Muting Pair

A company needed a way to safe-guard the area where pallets of empty bottles or cans enter into the depalletizer. Learn how Banner Engineering's XS26-2 Safety Controller with EZ-Screen safety light and LS-S safety light curtains helped maintain a continuous flow of pallets while protecting hazardous areas of a machine from workers.

Safe Material Access

In this application, a hazardous work cell is completely guarded to prevent personnel from entering the area. In order to allow parts and material to flow into the area efficiently, entry and exit zones will be left open. The EZ-SCREEN safety light screen is positioned in front of these zones and will stop the hazardous motion of the machine if an operator tries to reach or enter through these areas.

Safeguarding the Palletizer and Stretch Wrapper

Safeguarding areas around the palletizers and stretch wrappers can prove to be difficult because it involves multiple hazards. A scalable safety controller can help manage hazards related to the palletizer and stretch wrapper while ensuring efficient safeguarding processes.

Safety of a Plastic Film Heat Sealer

Learn how magnet switches protect operators from the harmful interior of a heat sealer.

Safeguarding Access Points to a Depalletizer

An LS Series safety light curtain with a mute arm kit in T-configuration combined with an XS26 Series safety controller is an easy-to-implement solution that protects staff from potential hazards without disrupting the flow of pallets to the depalletizer.

Safeguarding a Robotic Weld Cell

A robotic weld cell is protected on multiple sides by hard guarding. Between work cycles operators must be able to access the weld cell to retrieve completed work pieces and load new material. Used to safeguard access points to the weld cell, an SX5-B6 safety laser scanner can increase machine uptime and productivity.

Safeguarding a Pallet Transfer Conveyor

Pallet transfer conveyors are used to move heavy loads to the shipping area. Both the pallets and the conveyor pose risks for accident and injury and must be safeguarded. An SX5-B safety laser scanners safeguards the loading and unloading stations on the conveyor and enables a continuous flow of pallets through the system.

Monitoring Safety Doors on a Case Packer

Learn how SI-RF Series safety switches can be used to monitor multiple guard doors, ensuring the highest levels of safety, and making it easy to identify and resolve issues.

Safety Control on Small Machines

An SC10 Series safety controller replaces the functionality of three safety relays with one compact, cost-effective device offering intuitive operation and advanced capabilities.

Product Recall

Recalls happen, and when they do, it is critical that manufacturers respond quickly by identifying affected products and issuing a timely recall to mitigate damages.

Food Traceability and Safety

Food packaging facilities verify product barcodes at multiple points so they can quickly identify and isolate product with quality issues and ensure a safe food chain.

Pharmaceutical Traceability

Pharmaceutical traceability is required to eliminate counterfeits, ensure patient safety, and comply with regulations.

Work in Process (WIP) Tracking

Work in Process (WIP) tracking refers to tracking each item in production throughout the entire manufacturing process to ensure efficiency, accuracy, and traceability.

DPM Code Reading

Direct Part Marks (DPM) are codes that are etched or printed directly onto a part's surface. Due to poor contrast, they can be extremely challenging to read.

Barcode Presence and Rotation

An iVu BCR Series barcode reader with rotation range detection reads the barcode on medical product packaging and verifies that it is correctly aligned for heat sealing.

Barcode Reading on Pallet

Banner’s TCNM linear barcode scanner is recommended for scanning and validating the barcodes. It is able to decode over a dozen commonly used linear barcode symbols helping maintain an efficient flow of bottles along the production line. Utilizing the TCNM linear sensor allows for an automated way to confirm the correct product in real time.

Barcode Reading

ABR Series barcode readers can be used to solve track and trace applications, offering increased resolution to read smaller codes, over a larger target area, and at greater distances. Polarization is now available in both 1.3 MP and 2 MP ABR 7000 models for improved performance on targets with reflective surfaces or where glare is present. Our highest resolution camera, the VE is also available in only-barcode reading models, as well as the original vision camera-only model. This makes our VE series is the highest-resolution barcode reader in our portfolio, designed to better solve complex applications.

Tracking of Received Goods

Banner’s ABR barcode readers ABR Series barcode readers with a 2MP (1600 x 1200 pixels) imager reliably read small or complex barcodes, even at large distances or field of views, helping maintain accountability and an efficient flow of packages throughout a distribution center. The ABR barcode reader is ready to scan right out of the box with SMART TEACH push button for teaching codes directly on the device.

High-Speed 2D Barcode Inspection

Banner’s iVu BCR with remote display offers an easy to use solution for reading barcodes to ensure correct labels have been applied. The iVu BCR models provide both a fine mode, for reading smaller barcodes that require full resolution, and coarse mode, for applications where speed is critical.

Industrial Barcode Verification of Two Codes

Medicine bottle labels include both a linear and a 2-dimensional barcode. The PresencePLUS P4 BCR reads both types simultaneously to verify that they are correct.

Industrial Barcode Verification on a Cell Phone Component

The PresencePLUS P4 BCR industrial barcode scanner reads and verifies the small 2D bar code affixed to a component of a cell phone.

Pharmaceutical Product ID and Lot Control

The Pro, equipped wtih a barcode reader tool, enhances compliance with federal requirements for identifying and tracking pharmaceutical products.

Industrial Barcode Verification on Clear Labels

An iVu BCR with UV ring light is an ideal solution for detecting barcodes in a low contrast situation. The iVu is coupled with UV illumination for an all-in-one solution that improves contrast on clear labels so bar codes are easily detected.

Industrial Barcode Verification on a Metal Part

A PresencePLUS P4 BCR industrial barcode reader detects and verifies the subtle 2D barcode that was stamped into a metal gear so it can be tracked through production and in the field.

Intelligent Mail Industrial Barcode Reading

The iVu BCR is used in many mail applications to help direct mailers from multiple smaller runs as they are combined into larger ones.

Robotic Cell Industrial Barcode Inspection

It can be difficult and expensive to stop robotic operations to configure and monitor the barcode inspection process. An iVu BCR barcode reader with remote display can be mounted up to 16 m (50 feet) away from the sensor for remote monitoring and troubleshooting while the robot is in operation.

2D Stamped Industrial Barcode Verification

A PresencePLUS Pro barcode reader detects and verifies a subtle 2D barcode stamped into metal parts, despite variations in the stamped codes.

Verification of Two Barcodes on a Part

A part is tracked using both a linear and a 2-dimensional barcode. The high-resolution PresencePLUS P4 BCR 1.3 reads both types simultaneously to verify that they are correct.

Barcode Confirmation on Pallet

Shipping containers are often labeled with barcodes in order to more easily identify which product is present and ready to be shipped. A sensing solution needs to be present to confirm that the final, shrink-wrapped product is labeled correctly and matches the content inside.

Reliable Detection of Small 2D Codes on Pill Bottles

It is critical that 2D codes on pharmaceutical bottles are properly verified for product recalls and other quality assurance measures.

High-Performance ABR Reader for DPM Codes on Electronics

On electronic assembly lines, reliably identifying and reading small 2D Direct Part Marking (DPM) codes is essential. These information-dense codes track data at the component level, such as serial number and date of production.

Assembly

Pick-to-light systems support lean manufacturing initiatives by reducing the risk of human error in production and assembly processes.

Stocking and Replenishment

Put-to-light solutions improve the efficiency and accuracy of stocking and replenishment activities and can help prevent downtime by reducing delays due to misplaced or incorrect parts.

Kitting and Sequencing

Light-guided kitting and sequencing solutions allow operators to focus on building high-quality products while maintaining efficiency.

Order Fulfillment

Quick, accurate picking increases customer satisfaction by ensuring that customers receive the correct order in a timely manner.

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.

Pick-to-Light Kitting Support

Banner’s K50 Optical Pick-to-Light series is a compact, self-contained, three color indicator with integral sensor. Green typically indicates which part to pick, and when the internal sensor detects the hand, the indicator changes to yellow to confirm the task is complete. An optional third message is to display red for a mispick.

Order Fulfillment

The system controller issues an instruction to pick an item from a particular location. The controller turns on the PVA’s job lights at the specified location. The job lights go off when an item from that location is removed. If multiple items are required from one location, the job light stays on until the correct number of items are removed. The bright light of the EZ-LIGHT PVA pick-to-light sensor makes it possible to see which part to pick from a distance, saving time.

Pick Sequence Indication and Pick Verification

A pair of EZ-LIGHT PVA pick-to-light sensors are mounted to a rack on either side of a bin. In response to a signal from a process controller, the PVA illuminates to show the assembler which part to pick next. When the assembler's hand enters and leaves the bin, the controller recognizes that the part is picked and lights up the PVA for the next bin in the pick sequence.

Bin Coverage for Bin Picking Applications

The PVL provides 100% reliability over a large area and can be mounted directly to the racking profile. The PVL can also be mounted in a vertical or horizontal orientation to suite application needs. This versatility allows for a quick set up and quick and efficient processes.

Pick-to-Light Solutions

Several technologies and solutions are available for bin-picking applications for error-proofing processes. Light arrays prompt the operator for part selection with integral job lights, then reliably sense retrieval of the part, using an array of visible red or infrared sensing beams located in front of the bin.

Part Pick Verification for Large Bins

To reduce the risk of error in an assembly operation, a one-piece EZ-LIGHT PVD pick-to-light sensor is placed on the top rail of a shelf, looking down on the shelf opening. The PVD is interfaced with a process controller that is programmed to illuminate the PVD on the bin to pick. After the PVD detects that the assembler's hand has entered and left the bin, the controller signals the PVD on the next bin to pick.

Part Pick Verification for a Camera Lens

Each bin has an EZ-LIGHT VTB Verification Touch Button connected to a process controller programmed with each order manifest. The VTB's LED base glows to indicate which lens to select to fulfill an order. After selecting the lens, the worker places a finger in the touch zone of the VTB to verify the pick. The worker does not have to apply any pressure to, reducing the risk of repetitive motion injury.

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.

Order Fulfillment: Wide Shelf

Each wide shelf is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor in retroreflective mode, which has a range of up to 2 m. The PVD lights up on the bin from which the worker should select the map to ship.

Part Kitting

After the operator selects a washer or shim from a bin, the operator places the washer on the corresponding illuminated EZ-LIGHT indicator on a rolling cart.

Bin Picking for Order Fulfillment

In a book packing warehouse, the rack above each carton of books is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor. A worker fills orders by selecting the quantity of each book specified on the packing slip. To make it easier for the worker to find the cartons from which to pick books, the PVDs above those cartons are illuminated. The PVD detects the workers hand in the carton to verify that the title was picked.

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.

Improving Production with Pick-to-Light Systems

A Banner wireless solution is a simple way to optimize inventory, reduce errors, and minimize waste. Each Sure Cross Performance Node with I/O Mapping can be equipped with up to six EZ-LIGHT operator indicator lights. The Sure Cross Gateway is conveniently located at a central location where maintenance personnel and management can monitor the parts consumption throughout the site.

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.

Error-Proofing Assembly Applications

Banner’s K50 Series of single-point pick-to-light sensors are a simple, easy-to-use error-proofing solution in assembly applications. In this application, the job light is Green while the job input is active, indicating the correct bin for the next pick. The presence of the assembler’s hand initiates an output change of state, turning the job light red. The job light above the next pick location will then turn Green.

Incorrect Pick Signal

The EZ-LIGHT K50 sensor lights above a bin to show the assembler which part to pick. If the assembler reaches into a different bin, that bin's EZ-LIGHT K50 sensor lights up in the designated warning color—in this example, red— to indicate the error.

Part Pick Verification from a Wide Bin

The EZ-LIGHT K50 sensor in retroreflective mode indicates that the next part in the assembly sequence is the sunroof. When the operator selects the sunroof from its wide bin, the K50 detects the pick.

Part Pick Verification for Order Fulfillment

In an order fulfillment operation for a candy distributor, bins are equipped with EZ-LIGHT K50 sensors connected to a process controller programmed with the order. Based on the order, the K50 illuminates to show which items to pick. When the worker places a hand into the bin, the indicator detects the presence of the hand, and the controller triggers the K50 on the next bin to pick.

Pick Indication and Verification

Push-button EZ-LIGHT K50 pick-to-light sensors on a rack of parts light up to indicate which parts to pick. After picking a part, the worker pushes the button on the indicator light to verify that the pick is complete.

Quality Assurance at Multiproduct Assembly Workstations

Read more to learn how the Pick-to-Light Solutions Kit improved pick sequences and ensured a high level of quality assurance at mutiproduct assembly workstations.

Improving Productivity with Pick-to-Light Products

Learn how eFlex Systems empowered a hydraulic pump manufacturer with its turn-key platform and Banner's PTL110 pick-to-light devices to improve productivity and reduce errors in their assembly processes.

Machine Lighting

Well-lit machines are easier to monitor, troubleshoot, and maintain. Heavy duty LED lights are built-to-last in harsh environments and provide years of bright illumination.

Workstation and Area Lighting

Proper lighting reduces the risk of errors during assembly and inspection tasks, saving time and costs. Good lighting also improves worker ergonomics and reduces eye strain.

Enclosure Lighting

Compact LED lighting can help reduce errors and speed up maintenance tasks in confined spaces like equipment cabinets and other enclosures.

Visual Inspection

Visual inspection of parts and components helps manufacturers identify issues early to minimize wasted time and costs. In these applications, the right lighting is a must.

Illumination Plus Indication

An EZ-STATUS device includes both white and colored LEDs. The device can perform both task lighting and status indication functions with a single unit.

Work Light Strips for Bright Cabinet Illumination

Banner’s WLS28 Work Light Strips provide numerous energy-efficient solutions for illuminating work areas and enclosure interiors with intense, long-lasting and durable cool white light. These LED lighting strips not only provide even, extremely bright cabinet illumination, but they also conveniently fit in the enclosure and can be plugged into any local power source.

Amber Illumination Suitable for Photosensitive Materials

Illumination during photolithography processes is challenging because white light contains a percentage of blue wavelengths, which negatively affect photosensitive materials. The WLS15 strip lights switch between two colors for safe use during photolithography.

Machine Illumination for Inspection and Testing Procedures

Machine lighting inside of automated clinical labs helps operators see and access the samples and equipment being used inside. These types of environments can be difficult on traditional lights because of the reagents and chemicals used during testing and cleaning. The WLS28-2 is rated IP69K to withstand chemicals and washdowns.

Heavy-Duty Machine Lights in CNC Washdown Environment

Determining a lighting solution for the CNC machine is simple with Banner’s LED heavy-duty machine light, which provides enhanced chemical and thermal resistance in tough environments. The ultra-bright light is oil, chemical and water resistant with IP68, IP68g and IP69K ratings, making it an ideal choice for many industrial lighting applications, including the CNC washdown environment.

Illuminating Inside A Cartoner

Banner’s WLS28 LED Light Strips allow operators to identify frozen dinners that have not properly entered a carton and fix the problem with minimal downtime. Their long-lasting and durable cool white light means they’re an energy-efficient solution for illuminating the inside of a cartoner. IP69K rated, they can handle frequent machine wash down procedures.

Visually Control Intersections with Multicolor Strip Lights

Accidents can happen when people and mobile equipment share intersections in a factory. See how to create a controlled intersection with multicolor lights.

Illumination in High-Temperature Areas in a Paper Mill

Lighting inside of paper drying machines is helpful during maintenance and general operation of the paper production line, but illumination is difficult because of the high heat in the machine and the wet environment. The WLH60 high temperature LED light can withstand heats as high as 100° C and is rated IP67, IP68G, and IP69K for water, oil, and chemical resistance.

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.

Work Light for Pharmaceutical Packaging Inspection

Liquid-dosage pharmaceutical product packaging inspections involve minute human visual inspections, making it important to have bright and highly uniform illumination.

Illumination for Visual Inspection on a Printing Press

High visibility is critical during inspection of product in flexographic printing because the lighting assists in monitoring machine performance. The HLS27 LED Strip Light works well near flexography printing machines because they are designed to work safely in Division 2 hazardous locations. The bright light illuminates printing functions to assist visual inspection.

High-Quality LED Lighting for Workstations

Banner’s WLB32 Industrial Light Bar is ideal for workstations. With a Hi/Lo/Off switch, operators are able to control the lighting level and are able to switch the LED light bar off when they are done. The WLB32 provides workers high brightness with even light output and enables numerous tasks in a workstation, including working on a computer.

Highly Bright Illumination in Workstations

Banner’s WLS28 Work Light Strips with ON/OFF switches provide an energy-efficient solution for illuminating work areas and enclosure interiors with intense, long-lasting light. These LED lighting strips provide even, extremely bright illumination, and can easily fit in limited space setups. The work lights can be plugged into any local power source for simple operation.

Robotic Work Cell Lighting

The energy-efficient WLB72 Basic is bright, easy-to-install, and cost-effective for robotic work cell lighting.

Illumination at a Car Wash

WLS27 LED strip lights provide brilliant, even illumination in difficult environments like this. Each light is protected against environmental challenges and corrosion by a shatterproof, water-resistant polycarbonate shell. A redundant sealing method prevents water ingress to achieve IEC IP66, IP67, and IP69K ratings. These cost-effective LED light strips will provide vivid, low-power, maintenance-free illumination throughout their 50,000 hour or more lifespan.

Low-Bay LED Lighting

The heavy-duty, energy-saving WLB92 from Banner Engineering provides an extremely bright lighting solution that provides consistent lighting across a warehouse. Since the LED factory light is so bright and gives a uniform output, fewer lights are needed in total, helping reduce the overall cost of lights and installation time.

Highly Bright, Robust Lighting for Robotic Cells

Banner’s WLB32 Industrial LED Light Bar has a robust metal housing and shatterproof light cover, making it ideal for an industrial robotic cell environment. The WLB32 provides highly bright illumination, with a no-glare glow. Banner’s LED light bar is a better solution for industrial lighting compared to traditional fluorescent lighting. The LED light bar provides a directional lighting effect, dispersing light 120⁰, versus fluorescents, which disperse light 360⁰.

Semiconductor Process Tool Illumination

Banner’s WLS27 are rugged LED strip lights specifically developed to provide brilliant, even illumination in challenging environments and compact spaces. They have a space-saving, aerodynamic design, are fully encapsulated in a protective shell, and come in a broad range of illumination color options. Machine designers can install WLS27 LED strip lights wherever they are best suited to illuminate a work area without making costly or time consuming modifications to the lights.

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.

Bright LED Indication on Automatic Industrial Doors

WLB72 Inspection LED Light Bar

Banner’s WLB72 Inspection is a very bright LED luminaire that features an even light output for a no glare glow. This LED light bar uses advanced LED technology to provide a high-quality and maintenance free industrial lighting solution. The unique lensing provides a dark-to-light-to-dark transition on a vehicle surface suitable for detailed inspection tasks.

Product Changeover on Assembly Lines

The WLS27 Pro with IO-Link is one of two new models of the WLS27 Pro series strip light. It now includes programmable RGBW LEDs for use in indication, illumination, and inspection applications. Learn how the WLS27 Pro with IO-Link provided operators the necessary information and illumination to decrease product changeover times and maximize productivity.

Robotic Weld Cell Illumination

Learn how the WLS70 strip light provides bright, even illumination inside robotic weld cells.

Integrated Motion Switch for Hazardous Enclosures

In a recent oil and gas application, an oilfield supervisor was looking to install an overhead light within the enclosure.

Dynamic Status Indication

LED indicators with advanced programming capabilities can display dynamic statuses like fill level, takt time, machine transitional states, and more.

Illumination Plus Indication

An EZ-STATUS device includes both white and color LEDs. The device can perform both task lighting and status indication functions with a single unit.

Assembly Timer Indication at Automotive Assembly Station

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

Dynamic Maintenance Indication on a Beverage Line

TL50 Pro tower lights clearly informs operators that maintenance procedures are in progress with advanced action mode animation.

Truck Wash Efficiency Boosted by Visible Indication

Indicator lights intuitively direct traffic through truck wash stations to ensure efficient flow of vehicles through the wash. However, high-pressure washdowns, cleaning agents, and outdoor environments make status indication challenging. Learn why the WLS27 segmented strip lights are a better alternative to traditional stoplights and can help improve efficiency at truck wash stations.

Bright LED Indication on Automatic Industrial Doors

Star Equipment uses Banner's WLS27 multicolor LED strip lights with EZ-STATUS™ with their automated industrial doors for safer, more efficient movement in the workplace.

Automated Checkout Status

Learn how a retail store used TL50 Pro tower lights with USB to visually tell customers which automated checkouts were available for use, which were down for cleaning, and which were being used while they were waiting in long lines.

Operator Guidance Indication

Learn how a facility used WLS15 Pro with PICK-IQ to improve picking processes.

Operator Indication on Conveyor Systems

Learn how a facility used the K30 Pro Touch Button to improve operator control and guidance.

Material Handling Station Status

A facility manager in a recent material handling application needed to transport packages from the receiving end of the facility to the shipping end in an efficient manner.

Box Sealer Status Indication

A solution was needed to better indicate a variety of complex statuses coming from a labeling machine. Banner's CL50 Pro column lights are an effective way to provide at-a-glance status indication.

Level Measurement

Level measurement solutions assess fill levels and provide accurate, real-time data from a wide variety of containers or tanks.

Precision Measurement

Extremely tight tolerance requirements demand a reliable solution that measures parts in micrometers to detect small variations in part size, thickness, orientation, placement, and more.

Roll Diameter and Tension Control

Maintaining the correct level of tension on web materials ensures quality and reduces unplanned downtime. Measuring roll diameter is fundamental to maintaining appropriate web tension.

Web and Edge Guiding

Reliable web and edge guiding ensures a continuous flow of product through machine processes, minimizes downtime and prevents material damage and loss.

Liquid Level Monitoring

Banner’s U-GAGE QT50U ultrasonic analog long distance sensor has a narrow sensing beam that works in confined areas, such as the tank, without interference from the tank walls and senses with an extended range up to 8 m. The ultrasonic sensor can be mounted to the center so that the beam spreads over the tank to detect the fluid level without interference, while signaling when to pump out excess liquid and pump in additional liquid.

Liquid in Container Detection

Banner combined the technology of WORLD-BEAM QS30 opposed mode sensors, which provide high excess gain, with a 1450 nm infrared sensing beam—specially tuned to an absorption band of water, to create the QS30H2O Water Sensor. In this application, the powerful sensing beam of the QS30H2O will burn through the opaque plastic of the container. At 1450 nm, water absorbs 1,000 times the energy of alternative wavelengths, preventing the beam from burning through the liquid within the container.

Bottle Fill Level Detection

The Q4X analog sensor is set up in trigger mode and uses the averaging feature to provide a more consistent fill level measurement. Banner’s Q3X sensor, whose output wire is tied to the Q4X’s remote input wire, is used to detect the leading edge of the pill bottle and has a one-shot output timer setup based on the conveyor speed to determine when and how long the Q4X will measure.

Sheet Metal Thickness Measurement

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

Level Monitoring for Washdown Environments

Banner’s U-Gage QT50U ultrasonic sensor excels at the most challenging level applications, bouncing sound off any solid surface—even those that may vary in consistency or contrast. The sensor is available with a Teflon-coated transducer cover, making it resistant to harsh chemicals and suitable for the food and beverage industry. Ultrasonic sensors are able to provide accurate monitoring of pump-controlled tanks by sending a continuous signal to measure the current tank depth.

Level Monitoring On Rotary Filler System

Banner’s Sure Cross wireless system can easily transmit temperature, pressure and fill levels to a local PLCs. The wireless system will seamlessly alert operators if bottling is occurring below the desired fill level. This helps prevent errors and leads to greater consistency in bottled beverages. Consistent fill levels mean no recalls—and no wasted products. Using a wireless system also eliminates the need for slip rings on the rotary filler, which in turn reduces maintenance costs.

Day Tank Level Monitoring

Using a wireless level monitoring system, day tank fill levels are now monitored continuously so that materials are maintained at a specific quantity. Because these tanks are slowly filled or depleted, ultrasonic sensors can be used to measure the tank levels without false readings or tank wall interference. With a SureCross Wireless Network, FlexPower™ Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a T30UF ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. Remotely located tank sensor readings can be forwarded to a host system for data tracking, sending e-mail alerts, or to trigger specific events, such as refilling the tank. Tank resources are only filled when necessary to maintain customer-defined levels. Time is no longer wasted performing routine refills on tanks that did not need to be refilled.

Carton Stack Height

The two-point teach option on the Q4X analog laser measurement sensor is used to teach the full and empty magazine. Manual adjustment can be used to fine tune the output. The analog output provides a real time gauge of the stack height. This allows the cartoner machine to have several “call for parts” set points without having to manually move the sensor. The Q4X is a robust, rugged stainless steel sensor ideal for use in many industrial, factory environments.

Monitoring Flammable Fluid Levels in a Recycling Facility

Alternative data collection solutions are possible with Banner’s DX99 900 MHz radios in CID1 housings and the B/W Prostick magnetostrictive level devices. Using the appropriate antenna barrier, the result is a Class 1 Division 1 wireless monitoring solution that provides real-time data anywhere within the facility. With the battery powered DX99 units and the loop powered Prostick, installation into the 8' flanged tanks takes only a few minutes.

Case Stacker Inventory and Presence Detection

The two point teach option on the analog setting can be used teach the front of the flat cases as the 20 mA point and can easily be adjusted for a manual set of the 4 mA to the end of the cases. This helps gauge how many flat cases are left, so more cases can be added when the case count is getting low. The digital output can also be used for presence detection. This helps ensure there is a case available to be picked up, and also ensures only one box is picked up at a time.

Remote Fill Level Indicator

A brew pub uses EZ-LIGHT indicator lights as a remote display of the status of the levels in the brew tanks. The indicators are connected to ultrasonic sensors within the tanks that cannot be monitored easily.

Monitoring Salt Water Disposal Tanks

Automatically monitoring the tank levels and controlling the pumps out in the gas field eliminates human error and can more quickly prevent costly spills. When the battery of salt water tanks is filled, a signal is sent wirelessly from the tank battery to the field pump to shut down the well. When the tank battery and pump are separated by miles of terrain, Banner’s MultiHop radios are an ideal solution.

Wireless Tank Farm Monitoring in Unsafe or Harsh Conditions

With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.

Wireless Tank Level Analysis in Unsafe or Harsh Conditions

Banner’s SureCross DX99 wireless FlexPower Nodes offer Class I, II, and III, Division 1 and Zone 0 certifications for installations requiring Intrinsically Safe operation. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.

Tank Level, Pressure, and Temperature Monitoring

To wirelessly monitor and report level, pressure, and temperatures in the rotary fillers, each rotary filler was equipped with a FlexPower Node and DX81P6 6-pack battery supply. The FlexPower Node had two 0–20 mA analog inputs and one thermistor input while the battery pack supplied power to the Node and sensors for more than a year. A level probe, pressure transmitter, and thermistor (not supplied by Banner) were connected to the FlexPower Nodes and installed in the rotary tanks.

Fill Level of Dry Material in a Hopper

An L-GAGE LT3 laser distance-gauging sensor, mounted above the hopper, measures the distance to the material's irregular surface, enabling a PLC to calculate the bin’s fill level.

Indicating Pump Panel Status

Banner's tower lighting solutions, such as an EZ-LIGHT TL50 Tower Light, can be mounted on top of the pump panel to easily communicate the status of the pump. The highly visible light tower allows employees to quickly check the panel, without needing to open the panel door. Multiple lights can be on simultaneously, so several messages can be conveyed at once, and the audible alert provides indication that the pump is overheating and immediate attention is required.

Storage Tank Monitoring with a Wireless Network

Sensors connected to a wireless network monitor the fluid level in storage tanks. Because only 120V ac power is available at the tanks, the SureCross wireless network converts the available line power. The weather-resistant SureCross devices are protected against the elements, preventing time-consuming maintenance.

Liquid Soap Level Detection

The WORLD-BEAM QS18U ultrasonic sensor monitors the level of soap in a tank in a car wash. The sensor is mounted atop the reservoir, aiming through the transparent top. The sound waves bounce off the surface of the liquid.

Log Measurement

In this application, an EZ-ARRAY measuring light screen is being used to measure the length of the log. The EZ-ARRAY determines the total number of beams that are blocked by the log and communicates the length of the log to an operator station by sending the information to the system controller in the form of a MODBUS RTU-485 output. The operator station controller then provides a number of options to the operator, who selects which cuts are made.

Wireless Monitoring Retrofit in a Pre-Certified Facility

Sure Cross Nodes with FlexPower and Banner U-GAGE QT50U analog sensors quickly and easily facilitate these monitoring requirements without new construction and wiring. The FlexPower Node transmits the sensor data back to the Gateway device. When using a Gateway Pro, data is logged and alerts can be sent when fluid levels reach critical levels.

Wireless Water Treatment Monitoring in Unsafe or Harsh Conditions

In most waste water installations, the locations are not wired for power or data transfers. With a SureCross Wireless Network, FlexPower Nodes are deployed at each holding unit without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with an ultrasonic analog level sensor to operate for years on a single DX81 battery power supply.

Long-Range Position Detection

In a warehouse, the time-of-flight L-GAGE LT7 laser sensor gauges the position of a retrieval shuttle as far as 250 m away from the sensor.

Long-Range Feature Detection

Occasionally, work stations and conveyors do not have the space available to mount sensors close to the material they intend to detect. In these scenarios, a solution is needed that can detect small items from a long distance.

Tank Farm Monitoring

With a Sure Cross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with an ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. A DX80 FlexPower Node offers a combination of discrete and analog I/O in a single package, eliminating the need for time-consuming manual data collection.

Water, Waste Water, and Wireless Tank Monitoring

In most waste water or tank farm installations, the locations are not wired for power or data transfers. SureCross wireless Nodes and pressure or ultrasonic sensors can precisely monitor critical holding tank levels, sending data to a SureCross Gateway in a remote control center. Monitoring multiple data points including fill level, pH, conductivity, temperature, or flow is simplified using a single FlexPower Node with four analog inputs.

Fluid Level Control in a Forming Tank

To create a ceramic form, a vacuum is applied to a ceramic fiber suspended in an aqueous solution. Float mechanisms are ineffective for level control because the fiber adheres to the float, rendering it inoperable. Instead, a T30 UHPA ultrasonic sensor with pump in/pump out logic is used, with the power supply and 24 volt DC relay housed in a NEMA 12 enclosure behind the production line. The sensor is impervious to the washdown at the end of each shift.

Retrofitting a Lake Level Monitoring System

The existing lake level measurement system at Moncks Corner, South Carolina was aging and needed to be upgraded to newer technology. The new components, however, needed to use wireless technology for transmitting data to avoid having to run wire from the top of the dam to the dam office, located about a quarter of a mile away.

Water Tower Level Monitoring and Pump Control

A submersible pressure sensor and float switches connected to a FlexPower™ Node provide constant monitoring of water tower levels and wirelessly transmits data to a Gateway mounted near the pumps.

Monitoring Retention Pond Levels

Large facilities may have several runoff ponds in widely distributed locations. Using a wireless monitoring system eliminates the need for someone to drive out to each pond to monitor water levels.

Landfill Leachate and Ground Well Monitoring

A single FlexPower™ Node equipped with a counter input and submersible pressure sensor/transmitter can be used to reliably monitor both the leachate level and the pump. The submersible pressure transmitter monitors the leachate level while the counter counts pump strokes used to remove that leachate.

Controlling Pumps Using a Solar-Powered Repeater System

A Performance Mapping (PM2) Gateway and two PM2 Nodes (900 MHz, 1 W models), using the 1R mapping option, transmit the signal from the reservoir to the pump station. One of the Nodes was installed at the reservoir with the float switch as its input. A solar panel was used to power the float switch and the Node. The Gateway, also powered by a solar panel, was installed part way down the hill to act as a repeater and ensure the signal was strong between the reservoir and the pump station. The second Node was wired into the pump station’s PLC. When the signal from the float switch indicated the reservoir’s levels were low, the pump turned on.

Waste Water Management in a Land-fill Site

After careful consideration of several systems, the operators of the landfill determined that the Banner Wireless system was the only solution that could meet all imposed standards and seamlessly co-exist with other devices already in place at their site. With the help of integrator Wilson Mohr, they were able to create a system that could take data from below ground and make it accessible at the desk of the end user. One battery powered Node at the top of each well powers the radio and the ultrasonic analog level sensor. Each Node is equipped with a specialized low-power 4-20 mA analog level sensor and one 10-30V dc powered Gateway controls the system. The Data Radio and Modbus master controller module enhance portability of data and an omni-directional antenna extends the range of Gateway-Node communication up and over the hill and across the landfill site. Cutting-edge power management capabilities and an internal battery eliminate long haul cabling and create a greatly-reduced cost of installation. The wireless devices also have built-in diagnostic properties that send out alarms prior to complete shutdown, minimizing down time. They are also completely scalable and can adapt as the operators fill in and create new wells.

Non-Contact Fill Level Verification

Banner’s QS30H2O sensor is a specialized sensor developed to address challenges with sensing the presence of water and water-based liquids. The QS30H2O operates in a through beam sensing mode and the emitter uses a wavelength that is tuned to not pass through water. The high excess gain of the sensor makes it powerful enough to see through an assortment of plastic and glass containers. Two pairs of sensors can be utilized to determine that the fill level has met minimum but is not overfilled and wasting product. Apertures can be placed on the receiver end to minimize the beam pattern and increase accuracy of the application. This ensures products that do not meet fill level criteria are not processed or shipped.

Monitoring Content Levels inside a High-Volume Hopper

Banner’s LTF Series Laser Measurement Sensor features high excess gain, superior signal control and automatic adaptive laser power control. These features enable reliable detection of the chewing gum from up to 12 meters away, regardless of color or reflective surfaces inside the hopper.

Tire Production: Loop Control for Shiny Black Tread Rubber

Loops must be closely monitored and machine speed adjusted to maintain proper tension on the material.

Ensuring Part Presence and Position on Car Doors from Afar

High excess gain enables the sensor to detect items from an angle and it has very high accuracy, so even slight variations in target position will be detected.

Monitoring Plastic Tray Levels on a Denester Machine

Tracking tray levels on a denester machine ensures that product is replenished in a timely manner and does not affect production.

Tank Level Monitoring

Using K50U ultrasonic sensors and Q45U wireless nodes paired to a DXM100 wireless controller, we can develop a wireless monitoring system for multiple tank level measurements that is easy to set up, interpret the results, and monitor locally through a cloud-based system.

Roll Monitoring with a Laser Sensor

The L-GAGE LT7 is aimed at a roll of print paper, constantly monitoring its diameter, to gauge the rate at which the printer is taking up the paper.

Plastic Roll Diameter Measurement

Banner’s LE550 is factory configured with a range of 100 to 1000 mm and can start measuring immediately. If the range needs to be adjusted, the laser sensor has an intuitive user interface with a two-line, eight-character display, making it easy to automatically or manually adjust settings. The LE550 provides repeatability and accuracy across challenging targets, from metal to black rubber, allows for reliable measurement of the shrink wrap.

Efficient Paper Roll Measurement with Laser Sensors

After a convincing demonstration, the company chose Banner’s L-GAGE® LE550 laser gauging sensors to replace the ultrasonic sensors on their winders. Like the optical sensors, the LE550 is unaffected by drafts in the facility. Unlike the optical sensors, the LE550 is color insensitive. Linear array technology enables the LE550 to measure each roll, regardless of paper color, even colors that had most challenged the optical sensors.

Roll Diameter Measurement of Dark Material

Banner’s LE550 is factory configured with a range of 100 to 1000 mm and can start measuring immediately. If the range needs to be adjusted, the laser sensor has an intuitive user interface with a two-line, eight-character display, making it easy to automatically or manually adjust settings. The LE550 provides repeatability and accuracy across challenging targets, from metal to black rubber, allowing for reliable measurement of the dark blue material.

Sheet Metal Roll Diameter

Banner’s LE550 provides repeatability and accuracy across challenging targets, including shiny, reflective surfaces like metal. The laser sensor has an intuitive user interface, making it easy to adjust settings and set up a roll diameter application, without needing to unwind the metal roll. The analog output can be used to control wind or unwind speeds.

Tension Loop Control for Clear Plastic

The S18U Series Ultrasonic Sensor monitors loop control on a food packaging line to detect any breaks or tears in the clear plastic film. The S18U detects targets regardless of color or transparency.

Vertical Form Fill Seal Machine Solutions

Ultrasonic Sensor: Banner’s T30UX ultrasonic sensor delivers accurate distance sensing to provide a non-contact method to measure the roll of film’s diameter. By determining the roll’s radius, the vertical form fill seal machine can calculate the amount of film that remains and can signal the operator when it is low. The material should be advancing a predetermined distance equal to the desired length of each bag or package.

Loop Control of a Web

The D10 Expert detects the web if it droops into the sensor's beam because the tension is too loose; the D10 then sends a signal to the controller to adjust the speed accordingly.

Loop Control of Clear Plastic

The detection of clear plastic is always a challenge. The optical beam of traditional photoelectric sensors will burn through clear material, making sensing results unreliable.

Clear Material Loop Control

Banner’s T30UX ultrasonic sensor is the perfect sensor for detecting clear material for loop control because it uses sound rather than light, which makes it more accurate and cost-effective for this specific application. Although the material is clear, it presents a solid surface for an ultrasonic sensor to bounce a sound wave. The T30UX has a more accurate transducer, a smaller dead zone and minimum distance compared to other sensors that can be used for clear material detection.

Roll Diameter on Labels

In the beverage industry, labels need to be applied to the bottles quickly and without error to keep production levels high. Accurately monitoring the thickness on a spool of labels and controlling the unwinding speed is very important for the process to run smoothly. A solution is needed that can accurately supervise and report the material levels on a spool in order to prevent it from running out during the manufacturing process and delaying production.

Pick and Place Machine Leading Edge Detection

Fiber optics are an ideal solution for pick and place machines because of their small size. DF-G1 amplifiers can be separated from fibers so the operator has easy access to the digital dual-display screen for data monitoring. Additionally, the cross talk avoidance algorithm allows two or more amplifiers to operate in close proximity to each other.

Sizing, Profiling and Guiding Clear Objects

Banner Engineering has created a special class of EZ-ARRAYs specifically designed to detect clear objects in clean industrial environments. By customizing standard EZ-ARRAY receivers to successfully detect low contrast and operate at a lower sensing range (30 to 1500 mm), Banner has enabled EZ-ARRAY Clear Object Measuring Light Curtains to detect translucent objects such as glass and clear webbing.

Leading Edge Detection of Packages with a Thin, Flexible Edge

Banner’s LX Series is an economical solution for detecting the leading edge of flat objects, such as the frozen dinner containers. With a web of modulated light, the LX Series part-sensing light screen can detect any item—in any position—passing through the light screen.

Carpet Web Detection

It's much easier and more cost-effective to measure and monitor these transitions while the web is running than risk expensive waste in post-manufacturing inspections. As the carpet web passes through a pair of EZ-ARRAY measuring light curtains, the two sticks configured for Nap Detection mode monitor the process in action. The EZ-ARRAY detects the selvage edge and tufting edge and sends data to the web control system, which can then make necessary adjustments to keep the carpet in line.

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.

Loop Control for Clear Plastic

The analog U-GAGE S18U ultrasonic sensor positioned below a web of clear plastic monitors the tension of the loop, signaling the rate of uptake to increase or decrease as needed.

Edge Guiding for Battery Manufacturing

The DF-G3 fiber optic amplifier, used with plastic fibers, is a precise solution for edge guiding during lithium-ion battery assembly. Proper edge guiding reduces the amount of wasted product.

Electrode Film Edge Guiding for Battery Manufacturing

Challenge: Lithium-ion battery assembly combines rolls of anode, cathode, and separator film into a larger roll of electrode film. Precision edge guiding ensures that these three films are perfectly aligned when moving through steps in the process, such as coating, calendaring, and cutting.

Quality Control for EV Lithium Battery Electrode Thickness

Challenge: During the lithium battery manufacturing process, quality control is critical to reduce downtime and scrap: It’s also necessary to maintain high quality standards so the finished product functions as intended for its useful life.

Accurate Roll Diameter Measurement of Electrode Film

Challenge: In EV battery manufacturing, electrode material comes in the form of a thin plastic film, which is supplied in large rolls. This material presents challenging dark and reflective targets for traditional sensors,

Measuring Hopper Fill Levels with Radar

The Banner Engineering T30R radar sensor can be used to accurately measure the level of material in a hopper, for efficient and continuous production or packaging. The sensor uses radar, so it functions well even in the presence of dust or other airborne particles.

Level Monitoring in a Plastic Tank

A Banner Engineering T30R radar sensor can be used to accurately measure the amount of liquid inside a plastic tank.

Drive Thru Monitoring

A drive thru vehicle detection solution can alert employees to a customer’s presence at a window, count the number of cars passing through, monitor time spent in the drive thru, and more.

Traffic and Parking

Vehicle detection solutions for parking applications can reliably verify when a garage is full, activate a pay station, direct drivers to available parking spots, and more.

Car Wash

Vehicle sensing technologies verify that vehicles are correctly positioned in the car wash bay, monitor the flow of traffic, and trigger next steps like opening and closing doors.

Loading Docks

Vehicle detection at a loading dock can be used to identify available bays, facilitate fast load and unload times, verify vehicles are in the correct position before opening doors, and more.

Loading Dock and Mobile Pick-Up Solution Guide

Using K50U ultrasonic sensors and Q45U wireless nodes paired to a DXM100 wireless controller, we can develop a wireless monitoring system for multiple tank level measurements that is easy to set up, interpret the results, and monitor locally through a cloud-based system.

Vehicle Detection and Indication at Outdoor Docking Station

Detecting trucks and signalling arrival, wireless communication.

Ship Collision Avoidance and Traffic Monitoring in Harbors

Sensor solution required very long sensing range in a harsh weather conditions to monitor ships in ports.

Low-Power Vehicle Detection for Automated Car Wash

Wireless solution, remain in low-power standby mode until vehicle is detected.

Detection and Indication of Vehicle Arrival at Loading Dock

Outdoor vehicle detection in an environment not easily wired.

Vehicle Detection at Gated Community Exit

Wireless sensor solution to detect cars and automatically open gate in a gated community.

Monitoring Railcar Wheels Wirelessly

Detect the railcar wheels and trigger an axle pushing arm wirelessly.

Precise Vehicle Positioning in Extreme Car Wash

Detect vehicles as they travel through a car wash. Sensor solution with IP69K-rated housing and infrared light to burn through mist and steam.

STS Collision Avoidance

Sensing solution to detect cranes and warn operators of impending danger, preventing crane collisions.

Delivery Truck Detection at an Outdoor Loading Dock

Automated solution to help alert workers of a delivery truck's arrival through the use of shifts in magnetic fields.

Car Wash Status Indication Inside Washing Area

Sensor solution for bright indication inside a car wash, communicating various stages of the wash cycle.

Loading Dock Monitoring and Truck Presence Indication

Sensor solution to signal the presence of a truck at a dock door with bright illumination.

Vehicle Detection in a Self-Serve Car Wash

Solution to wirelessly detecting the entry and exit of cars in a car wash to reset a timer.

Remote Train Car Detection for Train Yard Mashalling

Wireless monitoring solution ssed at various points in a train yard to control direction of train cars.

Efficient Pay Station Activation upon Vehicle Arrival

Wireless sensor solution to detect the arrival of a vehicle in an outdoor environment.

Rubber Tire Gantry (RTG) Collision Avoidance

Since RTG cranes are hauling such large loads, it is vital to ensure they move safely throughout the port area to avoid collisions. A sensing solution is needed to effectively implement collision avoidance for port cranes.

Reliable Position Feedback for Empty Container Handlers

A transshipment company needed to streamline and improve their container transport process. Containers had to be quickly transferred from one means of transport to the next. Reach stackers would often collide with the containers, damaging themselves and the containers, resulting in unnecessary downtime and added costs.

Preventing Baggage Handling Equipment from Damaging Aircraft

Radar sensors help ground crews avoid equipment collisions with airplanes.

Use Radar Distance Measurement for Safe Truck Docking

T30R sensors can send truck distance data to a warning light for drivers.

Detecting Shiny, Reflective Wheel Parts

The T30R radar sensor from Banner Engineering can easily identify objects with reflective, curved surfaces, such as new automobile wheels in an assembly line.

Sensing Vehicle Position Within an Automated Car Wash

T30R sensors from Banner Engineering excel in vehicle-detection applications, even in harsh environments like car washes. As a radar sensor, the T30R detects the position of cars, trucks, and other large objects despite the presence of excess water, mist, and steam.

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.

Automated Quality Control

Automated quality control ensures consistent, reliable inspection of parts and components and helps manufacturers identify potential issues early on in the manufacturing process.

Error Proofing

Identifying the cause of errors and mistakes and correcting those conditions is fundamental to error proofing (poka yoke) and promotes a Lean manufacturing environment.

Refrigerated Breakfast Roll Detection on Multi-Lane Conveyor

Dark packaging with multiple colors transitions can be difficult to detect with traditional red LED sensors. Banner Engineering’s miniature VS8 photoelectric sensor with blue LED works well with low reflectivity labels to detect refrigerated food packaged in pressurized cans. The small sensors fit into tight spaces and work well for short range applications. The blue LED works with the small spot size to minimize the effects of color transitions on the labels.

Real-Time Adhesive Detection in PCB Assembly

Banner Engineering’s miniature VS8 sensor fits atop a glue gun to accurately detect the presence of adhesive as it is being applied. The VS8 is taught the distance between glue gun and PCB and can detect the very small height distance after the adhesive gets applied and recognize if there are any gaps or bubbles. The miniature sensors fit into tight spaces common in electronics assembly.

Detailed Inspection on a Sortation Conveyor

In large distribution facilities, sortation trays deliver products to the proper bin for correct shipment. Before sorting can begin, each tray needs to be empty so that items can be placed on the conveyor and sent to the next location. The 5mp VE Smart Camera recognizes very fine levels of detail and can detect items of almost any size, confirming the presence or absence of items on the trays.

Track Vials Through an Automated Clinical Laboratory

Banner Engineering's Q12 miniature self-contained sensor detects pucks that hold vials as they move through an automated clinical laboratory. Poor performing sensors could inadvertently cause errors and slow down the throughput of the lab. The Q12 is a good fit for clinical laboratories because it is small and can fit into confined spaces without affecting results. The fixed field sensor can also detect pucks regardless of color.

Error-Proofing Loading of IC Chips into Pocket Tape

• Confirm presence and orientation of IC chips • Sensor performs multiple functions at once • Cost savings and versatility

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.

Cap Orientation Verification

Banner’s Q4X laser sensor, made of 316L grade stainless steel, is very suitable for pharmaceutical environments and other aseptic filling areas. The Q4X has a sensing range of 25 to 300 mm, precise beam spot size and can effectively detect the orientation of caps as they exit a feeder bowl. If any caps are upside down, the Q4X will detect a height difference and reject the cap.

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.

High-Speed Tablet Counting With DF-G2

Banner’s DF-G2 small object detection fiber amplifier is ideal for small object detection and counting applications. The DF-G2 amplifier has a fast response speed and can detect extremely small sizes, such as 3 mm tablets or pills. When the tablets fall into bottles, it fires an output to the DF-G2 fiber amplifier, which keeps count of tablets.

Counting Gel-Caps in Pharmaceutical Bottling Applications

To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.

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.

Small Parts Counting

Banner's DF-G1 Series amplifier provides a simple setup and calibration for small part counting applications. Once the amplifier is setup, the easy-to-read digital dual display allows for simple operation because it shows the signal level and threshold simultaneously.

Call For Parts

Installing a signal to parts bins is a simple solution to keeping parts bins stocked and the assembly line productive. The EZ-LIGHT K80 Call Light is a large illuminated signal the operator turns on before parts are depleted. The K80 flashes red to signal stocking personnel to replenish bin supplies. In flexible manufacturing environments, operator stations and work cells must allow for quick changes to assembly and manufacturing lines.

High-Speed Soybean Counting

To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.

Electronic Marking Verification

The solution uses an iVu Series sensor configured for a Match inspection. A reference "good" identifier is taught into the sensor. In service on the production line, the sensor detects when a component does not have the correct identifier, and sends a fail output to the line, and the part is rejected.

Counting Dropping Parts with an LX Sensor

Banner Engineering's LX series part-sensing light screen generates a multi-beam infrared pattern that can detect any item passing through the beams, enabling exceptional sensitivity to small objects. As small parts drop from the feeder bowl into the plastic bag, the LX sensor detects each part and triggers the line to advance when the bag contains the specified number of parts.

Adhesive Bead Detection

The DF-GI amplifier, with the fiber optic sensing tip positioned near where the robot applies the adhesive, verifies that adhesive is applied to the IC chips. Opposed pairs of VS2 sensors detect when the level of filled wafer trays exceeds a preset height.

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.

Package Inspection Using Diffuse-Mode Laser Sensors

A WORLD-BEAM QS18LD diffuse-mode laser sensor can be used to accurately inspect each package as it passes on a conveyor. The sensor emits a visible Class 1 laser sensing beam, focused on the piece of tape used to seal the package. When the top of the box is closed and sealed correctly, the tape will return the sensing beam back to the receiver.

Part Loaded Indicator

Before the EZ-LIGHT K50L indicator light was installed, the operator would place a part on the machine and then step out of the work area to check the stack light to see if the part was loaded properly. If not, the operator had to repeat the set-and-check process before initiating the machine's action on the part. Since the K50L was installed inside the workstation, using a simple Y splice, the operator can tell immediately if the part is correctly placed.

Part Detection for Error-Proofing

To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. In this application, the operator removes a cap and drops it through a funnel. The cap is then detected by the Small Object Counter, which verifies that the cap has been removed so the assembly process can continue.

Cap Sorter Detection

Banner’s R55F fiber optic sensors have the capability to detect the presence of caps regardless of their color or size – a clear advantage in an industry that has a wide variety of bottle caps and frequent line changes. In this type of application, the fiber optic sensors are used to recognize long pauses between the caps which would then signal a jam to the operators of the machine. The fibers are compact and can be easily mounted in confined and typically inaccessible spaces.

Close Proximity Error Proofing on Assembly Line

Banner’s Q4X analog sensor can give operators real-time measurement feedback to verify the part is present and correctly positioned before moving to the next operation. In this application it is crucial that both flanges around the weld nut are properly seated in order to fit correctly in the final assembly. The Q4X’s analog measurement can determine if both flanges are properly seated.

Checkweigh Station Indication of Pass/Fail Status

Alert operators of the fail status on a checkweigh station on a food processing line in a harsh washdown environment.

Black Plastic Tray Detection at a Hopper and Filling Station

Learn how the Q4X detects dark colored trays at hopper and filling station in the food industry.

Flap Detection on Packaged Frozen Dinners

The QS18LD laser diffuse sensor scans across the top of the package to see if any flaps are open. The laser diffuse sensor provides accurate detection to verify whether the frozen packages are sealed properly.

Date/Lot Code Verification on Food Cartons

Banner’s rugged PresencePLUS P4 Sealed OMNI vision sensor works well for date/lot codes because it uses Optical Character Verification/OCV inspection to ensure the correct day and lot code are printed legibly. With an IP68-rated housing, the sensor is ideal in food and beverage applications because it can withstand harsh wash-down environments. The P4 OMNI sensor easily locates the region of the carton magazine that needs to be inspected for date/lot codes by verifying the edge of the box. Wi

Indication and Touch Actuation on Work Cell Assembly

The unique indication of the programmable K50 Pro touch buttons and Pro Editor software allows for versatile indication of numerous machine statuses and in-field customization. Multicolor and animation allow for quick identification of errors in work cells.

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.

Identifying Presence and Height of a Bottle Cap

The iVu Plus Gen 2 vision system, paired with a Q4X and LEDRB backlight, offer a solution that will provide dependable results.

Blister Pack Inspection

To verify each blister in the pack, use an iVu Series sensor configured for an Area inspection. The sensor inspects each blister pack to make sure that each blister contains an unbroken tablet.

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.

Inspecting Tablet Placement Quality in Blister Packs

A single VE Series Smart Camera, adjacent to the machine’s outfeed, inspects multiple rows of blister pack trays in a single inspection. The camera is installed approximately 36 cm over the production line and an LED backlight is installed 10 cm below the production line.

Detection of Cap Orientation

The Banner Q3X laser diffuse sensor is ideal for applications that require orientation detection with small contrast differences.

Black O-Ring Detection

The Q3X is Banner’s rugged, versatile laser contrast sensor, ideal for applications that require fast detection. As parts go down the conveyor, the Q3X will be able to detect if the o-ring is present based on the taught contrast differences. If the o-ring is not present, the Q3X will see a bright signal level and send an output to the PLC. This alerts operators to fix the error or move the part off of the production line.

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.

Punch Hole Inspection

To verify that the expected number of holes exist on a small metal part that is not rigidly fixed, use an iVu Series sensor configured for an Area with Motion application. 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.

Verifying Product Logo on Paperboard Packaging

A VE Series Smart Camera inspects the product logo on each box before the tube of toothpaste is inserted. As a box enters the inspection area, it is detected by a sensor on the line and an output is sent to the trigger input on the camera, which captures an image of the region of interest (ROI). A red LED ring light powered by the camera enhances the contrast between the product logo and the surrounding packaging.

Date/Lot Code Inspection

To verify each package has a date/lot code printed on it, an iVu Series sensor is configured for a Match inspection. An image of the date/lot code is captured. When the inspection is running, if the sensor detects a package without the date/lot code the sensor sends a fail output to the line, and the product is rejected.

Food Packaging Label Inspection

To verify each box is correct, an iVu Series sensor is configured for a Match inspection with 360 degree rotation enabled. An image of the correct box is captured and when the inspection is running, if the sensor detects an incorrect box, the sensor sends a fail output to the line, and the product is rejected.

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.

Box Insert Detection

To confirm that each unit includes a product information insert, an iVu Series sensor is mounted above the packaging line. The sensor is configured for a Match inspection, and checks that the product information leaflet is inserted into each package of medication. The leaflet can be placed in any orientation, but must beface up.The sensor can detect 360 degrees of rotation to find the insert.

Inspection of Stoppers in Vials for Correct Seal

To ensure that a stopper is properly inserted as each vial leaves the filling station, an iVu Series sensor—set up for an Area with Motion application—verifies that the vial has a stopper inserted into its neck and that the stopper is positioned correctly to provide a proper seal on the glass vial. If the stopper is missing or incorrectly positioned, then the sensor sends a fail output to the line.

Label Inspection in a Wet Environment

A sealed PresencePLUS Pro COLOR vision sensor is encased in an enclosure that protects it from damage in a wet environment. The Pro checks for label presence and placement.

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.

Label Inspection

To verify each product, an iVu Series sensor is configured for a Match inspection. An image of a good product package is captured. When the inspection is running, if the sensor detects a package with a different or missing label, the sensor sends a fail output to the line, and the product is rejected.

Wafer Center Detection with DF-G2

By pairing Banner’s DF-G2 with four opposed mode PLIS-1 fiber optics, operators can ensure that a wafer is placed correctly on the end effecter of a robotic arm, ensuring that no damage is done when passing it into the chamber.

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.

Part Orientation

An iVu vision sensor inspects nuts exiting a vibratory feeder bowl to ensure that the correct side of the nut faces up. The iVu features an intuitive operating environment that makes it easy for users to quickly apply and support inspections on the device.

Small Part Inspection in Tough Location

Banner Engineering’s iVu vision sensor inspects presence vent tubes and spreader washers on a busy bottling line. It uses a 50 mm C-Mount lens to extend the working range of the sensor to avoid contact with spray and liquids.

Solder Ball Inspection

To verify each integrated circuit, this application uses an iVu Series sensor configured for an Area with Motion application. If the sensor detects a part with missing or damaged solder balls, or if it detects any foreign material, the sensor sends a fail output to the line, and the part is rejected.

Pharmaceutical Insert Verification

An iVu BCR sensor is mounted 8-12 inches above a conveyor of boxed pill bottles containing a medical information insert. The iVu BCR industrial bar code scanner reads a data matrix code on the insert to verify it matches the product on the packaging line. When a box containing an incorrect insert or no insert at all moves past the iVu BCR inspection area, the iVu detects this fail condition and sends an output alarm to the production line.

Blemish Detection on Bandage

iVu Series vision sensors are ideal for monitoring materials to ensure that specific quality standards are met. It provides users with complete control and immediate feedback for setup and monitoring of products. It features multiple sensor types, including a blemish sensor, which is the best mode for this application.

Glass Vial Chip Inspection

The solution uses a PresencePLUS P4 OMNI, a Standard 16 mm lens, and an On-Axis Diffused LED light. A Geometric Count tool that was used to build the inspection searches the entire image for the pattern of a good vial. The pattern consists of edge outlines of the inside and outside diameters (ID and OD) of the vial opening. A mask is used to remove the reflection from the inside bottom of the vial.

Detecting Tamper-Evident Band Position and Presence

Banner iVu TG vision sensor with multi-point inspections is ideal for detecting and evaluating the position of tamper-evident bands. In this application, the band should be positioned around both the cap and the neck of a bottle. A seal positioned too high, too low, or completely missing would be considered unacceptable. With multi-point inspection, the iVu TG vision sensor can simultaneously detect missing and poorly positioned bands.

Parts Inspection on a Feeder Bowl Rail

In this illustration, precision machined bolts have just come out of the feeder bowl and are moving down the feeder bowl rail, conveying to the next automated step. As they move down the rail, a WORLD-BEAM QS18 detects the bolt and sends a triggering signal to an inspection sensor, the iVu Image Sensor. The iVu is configured to detect a flaw in the flange, irregular shape of the bolt head, or other flaws that might be present.

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.

Position Verification for Vial Filling

It is critical to verify the position of the stoppers since improperly sealed or positioned stoppering can compromise the product's integrity. Vision inspection offers a flexible, powerful, and effective method to inspect for seal quality and stopper position for the vial filling process. For stoppers with full insertion, we are looking for the minimal amount of gap between the bottom of a stopper relative to the top of a vial.

Correct Label Verification

An iVu TG Image Sensor works well for label verification because it comes with four sensor types, including a match sensor. The match sensor determines whether a pattern on a label matches a reference pattern and if it is correctly oriented. With just the touch of a button—or remotely through a PLC—users can easily teach the iVu image sensor to recognize and match the correct label pattern, requiring no image processing expertise.

Hard Disk Detection

Because disk surfaces are shiny, many sensors have difficulty detecting whether a hard disk is properly seated in a hard drive. Banner Engineering’s Q3X and Q4X sensors are designed to detect shiny surfaces with a wide variety of colors, textures, and materials.

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.

Shrink Sleeve Label Presence and Correct Label Verification

The P4 OMNI vision camera is located immediately after the bottles leave the labeler which assures that the presentation of the label will be in a repeatable manner and therefore can be compared to a stored image for a match. The P4 OMNI is sealed to IP68 and made with nickel plated zinc housing.

Color Inspection and Verification

A PresencePLUS Pro COLOR vision sensor verifies that pour spouts inserted into detergent bottles are present, fully inserted, and the same color as the bottle. The IP68 sealed housing protects the sensor and ring light from liquids.

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.

Full Case Detection and Cap Color Inspection

A PresencePLUS P4 COLOR OMNI vision sensor verifies that a case is fully packed with bottles with matching bottle caps. The sensor detects whether any bottles are missing from the case, whether any bottles are uncapped, and whether any caps are the wrong color.

Detecting Plastic Wrap on a Can

In the application shown, the plastic wrap surrounding the cap and the top of the can serves several purposes: it acts as a tamper-proof seal on the can, it prevents the cap from disconnecting during transit, and it holds the applicator tool to the can. Additionally, the plastic serves as error-proofing to protect customers from spilling the contents before they are ready to use it. For these reasons it is important that cans without the plastic wrap are rejected.

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.

Orientation Verification

This application uses an iVu Series sensor configured for a Match inspection. It ensures that the music label is face up and within a small rotational tolerance. If the sensor detects a CD that is incorrectly oriented, it sends a failure to the line, and the CD is rejected.

Blister Pack Inspection by Color

Tightened federal regulations make the quality of pharmaceutical packaging increasingly critical. A PresencePLUS Pro COLOR vision sensor inspects blister packs to make sure each blister contains the correct tablet and that the tablet is not broken. It also detects empty blisters and those containing foreign matter.

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.

High-Speed Bottle Inspection with PresencePlus

To rapidly verify that beer bottles are filled to the correct level and that caps are correctly aligned, a high-speed PresencePLUS P4 vision sensor locates the bottle and verifies the fill level and cap placement. This helps eliminate the need for multiple sensors, while accurately detecting the presence of caps and monitoring fill level. The red backlight provides a strong contrast to the bottles, amplifying the bottle features for easy detection.

Food Packaging Inspection

A high-resolution PresencePLUS P4 OMNI 1.3 mounted above a conveyor inspects each box of 12 chocolate candies, making sure each paper nest contains one candy and that the candy is intact.

Detecting Bottle Caps of Various Colors

As plastic bottles pass below the WORLD-BEAM Q12 Sensor, the fixed-field beam identifies bottles with caps—no matter what their color—and rejects bottles that are missing caps from the line. The Q12’s laser-like LED beam sharply cutoffs at 15 mm, 30 mm and 50 mm range, ensuring it won’t mistake objects inside the bottle for caps.

Cap Inspection in Confined Areas

The rugged PW12-rated World-Beam Q12 sensor inspects bottle closures using fixed-field technology to ignore cap color changes. With many types of bottles and product coming down the line, it is important for the sensor to ignore the size of the cap whether it is 25 or 50 mm. Using the same fixed-field technology, the Q12 easily ignores color and size changes in caps, while detecting whether or not a cap is present.

Part Flaw Detection

To verify an electronic component like that shown, an image of a good part was captured using an iVu Series sensor configured for a Match inspection. If the sensor detects a part with a bent or missing connector, or if the part is wrong side up, the sensor sends a fail output to the line, and the part is rejected.

Bottle Cap Inspection

After bottles are filled and capped, they are conveyed under the WORLD-BEAM Q12 sensor at close range, before they are packed in cartons. The Q12 sensor, operating in fixed-field mode, detects missing or misaligned caps—regardless of color—and triggers the line to reject uncapped bottles. Because the sensor uses fixed-field mode, it responds when a cap is not at the exact distance from the sensor that it should be.

Code Inspection on Clear Bottles

A PresencePLUS OMNI inspects the neck of a clear plastic bottle to verify that the date/lot code has been imprinted on the bottle. It also confirms that the cap is properly applied and that the bottle's fill level is within the acceptable range.

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.

Labeling Detection

In an application with limited space, the WORLD-BEAM Q20 sensor is easily positioned to verify the presence of a label before it is applied to the product.

Injection Molding Inspection

The solution involves using an iVu Series sensor configured for a Match inspection. The sensor evaluates each plastic bottle and, if the bottle is not well formed, the sensor sends a fail output to the line where the plastic bottle is rejected.

Vial Placement Verification

After a technician places vials in a tray based on each vial's color-coded lid, a PresencePLUS P4 COLOR OMNI verifies that the pattern of colored vial lids is correct.

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.

Candy Color Inspection

A PresencePLUS P4 COLOR OMNI mounted about a conveyor inspects each box of 12 chocolates, making sure each paper nest contains the correct type of candy, based on color. It rejects boxes that have the wrong chocolate in a nest, are missing product or have damaged product.

Color Inspection of Pour Spouts

A PresencePLUS P4 COLOR OMNI vision sensor inspects pour spouts that have been inserted into detergent bottles. The sensors verify that the spout is present and inserted fully, and that spout color matches the bottle color. A special bracket positions the area light at an angle that maximizes contrast and color visibility.

Label Alignment Inspection

As each salad dressing bottle leaves the label station, an iVu Series vision sensor, configured to use the Match tool, inspects the label, comparing it to a preconfigured reference image to ensure that the label is present and has been correctly applied.

Capping and Fill Inspection

As glass bottles pass on a high-speed conveyor, a PresencePLUS P4 COLOR OMNI confirms that each bottle is completely filled and makes sure that the stopper is fully inserted and is the correct color. The dual area lights create the optimum contrast for the inspection.

Inspecting for Missing Chocolates on a Packaging Line

Banner sensors are positioned above a conveyor inspecting each passing box for missing chocolates. When a passing box breaks the trigger beam created by a pair of Q12 opposed-mode sensors, an array of QS18AF sensors mounted above the box inspect each location for missing chocolates. When a box containing the wrong amount of chocolates is detected, an output signal is relayed to a main controller at the packaging line warning of the failed condition.

Inspecting Bottles for Cap Presence and Correct Color

To ensure that product quality standards are met and that product appearance is consistent with the brand, the company must inspect each bottle to ensure that the right bottle cap is present and properly seated.

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.

Fine Detail Inspection of Mobile Electronic Devices

Cell phones and other mobile electronics have densely populated components on their printed circuit boards. A VE Smart Camera is used to capture all the fine details and ensure that all components are present and placed correctly. Using a camera eliminates the risk of human error and prevents malfunctions and recalls.

Reliable Blister Pack Tablet Verification with Color Sensors

How anti-glare color sensors reliably verify tablet presence and color through reflective blister packs.

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.

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