All Assembly and Robotics Solutions

  1. Detecting Black Parts on Black Door Panel

    Banner’s Q4X problem-solving triangulation-based laser sensor has no difficulty detecting dark targets on dark backgrounds when there is a height difference. The Q4X provides a reliable sensing solution with best in class excess gain and makes pass/fail judgments based on distance rather than color or reflectivity.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. LED Lights Illuminate Control Cabinet

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

  7. Superior Light Distribution with LEDs [Success Story]

    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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  21. 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.

  22. 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.

  23. 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.

  24. Reducing Production Errors with a Pick-to-Light System

    A supplier of door panels to a global car manufacturer wanted to implement a pick-to-light system to reduce errors and the lost time that results from picking the wrong part during assembly.

  25. Improving Production with Pick-to-Light Systems

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

  26. 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.

  27. 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.

  28. 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.

  29. Vision Sensor to Read QR Codes [Success Story]

    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.

  30. Small Assembly Station Protection

    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.

  31. Dual-operator Robotic Work Station

    Banner Engineering’s EZ-SCREEN LS is able to address the challenges of safeguarding multiple access points to a hazard with its automatic cascade feature. This advanced feature allows up to four light screen sets, of any size and resolution, to be connected in a series with as few as one cable to lead back to the control cabinet and one single dual channel safety interface, saving panel space.

  32. 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.

  33. 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.

  34. 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.

  35. 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.

  36. 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.

  37. 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.

  38. Safeguarding of a Power Press

    Banner’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. Additionally, its 12 meter range ensures it can guard large presses and overcome optical degradation due to oil and dust accumulation on the window, which can typically accumulate on the machine and weaken the system’s performance.

  39. 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.

  40. 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

  41. Call for Parts, Service, or Pallet Pickup

    • Increase efficiency using a wireless call-for-parts/service/pickup system • Connect up to 18 work stations with six forklifts/Hi-Los • Resolve critical issues quickly without disrupting workflow

  42. Equipment Monitoring from a Supervisor's Station

    • Provide at-a-glance machine status indication • Send machine status information to a wide range of devices • Alert staff and supervisors of critical conditions via text message or email

  43. Restocking Assembly Stations for a Continuous Workflow

    • Restock assembly stations before components run out without overstocking • Provide real-time communication between assemblers and the forklift operators who supply them • Monitor delivery efficiency

  44. 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

  45. 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

  46. Remote Monitoring to Optimize Overall Equipment Effectiveness

    • Provide instant visual communication across a busy plant floor • Collect machine status and other data to calculate Overall Equipment Effectiveness (OEE) • Alert staff to critical conditions via text message or email

  47. Environmental Monitoring inside a Machine Control Panel

    • Identify small problems before they become major issues that impact machine performance and uptime • Access environmental data from a remote location • Notify operators of critical conditions via text message or email

  48. Condition Monitoring for Predictive and Preventative Maintenance

    • Identify machine problems before they cause serious damage or unplanned downtime • Alert staff of changes in condition via text message or email • Provide at-a-glance local indication of machine status

  49. Wireless Pick-to-Light System for Mobile Assembly Stations

    • Minimize production errors by providing clear guidance for assembly • Reconfigure and move assembly stations without rewiring • Improve production efficiency and better utilize facility space

  50. Improve Overall Equipment Effectiveness by Monitoring Production Input and Output

    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.

  51. Multicolor Indicators and Illuminated Touch Buttons Simplify Machine Panels

    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.

  52. Inspecting Small Connectors [Success Story]

    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.

  53. Sensors to Measure Movement Range

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

  54. 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.

  55. 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.

  56. Robotic Work Cell Lighting

    The energy-efficient WLB92 is easy to install and accommodates a wide variety of application needs with several models available. The light is extremely bright; effectively illuminating a robotic cell area. AC conduit models provide easy installation throughout the cell. The high-quality WLB92 LED light was designed to have an aesthetically-pleasing look, yet be rugged enough for industrial environments.

  57. LED Light Bars Outshine Fluorescents, Reduce Machine Build Times & Expenses [Success Story]

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

  58. 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.

  59. 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.

  60. Remote Monitoring Calculates Machine Run Time [Success Story]

    During normal operation, operators load a welding machine with the frame components to be welded. The customer needed accurate machine run time data to determine why production goals were not being met.

  61. Streamlining Call for Parts or Service [Success Story]

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

  62. Communication in a Busy Manufacturing Site [Success Story]

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

  63. Call for Parts

    Banner’s rugged, cost-effective and easy-to-install K30 Touch pick-to-light indicators are ideal for these applications because they are easy to actuate with the touch of a finger and can help industrial automation manufacturers reduce the error risk. They can be actuated with either bare hands or work gloves.

  64. Increasing Efficiency on Production Lines

    By installing DX70 pairs, tower lights, and switch boxes, manufacturers can create a wireless notification network and communicate across the factory floor. Operators can flip switches to call a manager to the production line, call a technician, or even request parts or supplies. Using the tower light notification system reduces the need for clerks, technicians, or managers to be constantly checking each production line.

  65. Stack Height Detection of Metal Parts

    Transfer presses require reliable part-out or feed sensing to keep the mechanical shuttle system going without causing tool damage or producing low-quality parts. If the placement or movement of metal sheets is not precisely controlled, it could result in downtime and large quantities of scrap.

  66. Bright Indication in Ambient Light

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

  67. Emergency Stopping (end-mounted rope pull)

    Banner offers various rope pull switches in spans of 6 to 100 meters, so they can run along the length of various conveyor belts. The rope pulls switches also feature heavy-duty housings suitable for harsh environments. In emergency situations, the operator can pull the rope from anywhere along the line to immediately stop the conveyor and hazardous action.

  68. Emergency Stopping (center-mounted rope pull)

    The pull rope runs along the length of a conveyor so the operator can grab and pull it from anywhere along its length to immediately stop the conveyor.

  69. Calling an AGV for Parts

    DX80 SureCross Wireless products are a great way to communicate with automated guide vehicles in a wide variety of industries. Remote, self-contained push buttons attached to SureCross Wireless Nodes can be placed at assembly line workstations. When a specific part is needed, the push buttons can be activated and a signal sent to a Wireless Gateway-equipped AGV for replenishment of parts.

  70. Automatic Storage & Retrieval System

    SureCross FlexPower™ Nodes and low-power sensors combine to create a portable monitoring system that instantly integrates with existing Automatic Storage and Retrieval System (AS/RS) cranes. The combination of Banner’s reliable wireless solution and unique power management capability creates a host of simplified monitoring applications onboard the AS/RS crane. The FlexPower battery pack supplies power to the Node and up to four low-power sensors for years of operation. Preventative maintenance concerns can be addressed with a FlexPower Node equipped with multiple thermocouples for monitoring motor or critical bearing temperature. The communication output on the Gateway (system controller) can be used to create historical logs or trends to verify the equipment is operating at peak performance. Crane motion can be announced to staff with an EZ-LIGHT™ indicator at the end of each aisle. This bi-directional monitoring system is a simple way to alert employees that a crane is in motion without requiring any new construction or expensive downtime.

  71. Call for Parts (Put to Light)

    When the supply of parts runs low, the assembler presses the EZ-LIGHT K50 push button to the left, which is used as a call button to signal to the runner to bring more parts. The K50 light to the right is used as a part-pick indicator.

  72. Retrofit for Robotics

    The DX80 Gateway is positioned at the control panel to collect and process data. A DX80 Node, DX81 Battery Module, and I/O block are attached to the robotic arm. The Node allows for data gathering at the robot's end effector and also comes available with an M23 connector. The DX81 Battery Module provides power for both the Node and one external input device. These devices are easily integrated with existing equipment.

  73. Call for Parts or Service

    Small indicator lights, such as light towers, can be mounted on each workstation allowing assembly workers to quickly and easily communicate to workers on the floor. In this case, a Banner TL30 tower light is mounted at each station allowing the assembler to call for additional parts or personal assistance without interrupting the production process.

  74. Increasing Production Line Efficiency

    An electronic component assembler needed to increase the efficiency of its production lines by reducing the amount of time technicians and managers were away from their work stations. The previous system required operators to manually walk over to the manager area to request more work or assistance with a technical issue.

  75. Call for Parts at a Furniture Manufacturer

    The customer needs a solution that can increase the forklift operator's response time by putting indicators on the forklift's dashboard and can also allow the forklift operator to acknowledge the request, which eliminates redundant part deliveries by multiple operators.

  76. Presence Detection on Rotating Lathe Turret [Success Story]

    Betty Machine chose the SureCross® DX80 FlexPower® wireless network from Banner Engineering. This versatile, highly-scalable solution is built around a Gateway capable of two-way communication with multiple end-point Nodes.

  77. Adding Run, Stop, and Bypass Capabilities on a Robotic Work Cell

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