Pharmaceutical and Medical: Primary Packaging
Used on bottle fillers, tablet dispensing machines, desiccant dispensing machines, blister packaging machines, and other unit dosage packaging equipment, Banner sensors solve a number of challenging applications. They can be used to verify bottle position at filling stations and to monitor the dispensing and hopper levels of drugs. Vision systems verify that blister packs are completely and correctly filled and inspect stopper position and height to ensure that containers are sealed properly. Clear object detection sensors reliably detect clear glass or plastic bottles, vials, syringes, and ampoules used to package liquid dosage products. Our unique liquid detection sensors inspect fill level to ensure products are not under filled or over filled.
Banner’s iVu Plus BCR Gen 2 with remote display offers an easy to use solution for reading barcodes to ensure correct labels have been applied. The iVu Plus BCR Gen 2 models provide both a fine mode, for reading smaller barcodes that require full resolution, and coarse mode, for applications where speed is critical.
Banner’s TCNM linear barcode scanner quickly and easily detects up to 10 linear barcodes on packages, helping maintain accountability and an efficient flow of packages throughout a distribution center. The TCNM linear barcode scanner is ready to scan right out of the box with SMART TEACH, providing scan rates of 500 to 1,000 scans per second. The linear barcode scanner can read barcodes in ranges from 40 to 600 mm.
The iVu BCR barcode reader scans pallets as they are loaded, identifying that pallets are complete. This ensures that operators know what truck or warehouse location the completed pallet will be directed. After the iVu BCR barcode reader verifies the pallet, the pallet is taken to the warehouse for storage or loading dock for shipment. Banner Engineering’s iVu BCR barcode reader decodes a variety of barcodes, including DataMatrix, Code 128, Code 39, Codabar and many more.
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.
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.
A SureCross 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.
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.
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.
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.
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.
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.
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.
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.
The LH laser displacement sensor is a perfect solution because it is highly accurate and measures thickness at micron levels. The L-GAGE LH Series can also consistently look at dark targets on these levels. The LH’s 1024 pixel CMOS linear imager is capable of micrometer-level resolutions ranging from 1-10 microns, which gives it the ability to measure thickness of sheet metal quickly and accurately.
Banner’s time-of-flight LT7 laser sensors provide long-distance ranges up to 250 m with a visible red laser spot for easy alignment. Depending on range needed, a diffuse or retroreflective time-of-flight laser sensor can be used. Retroreflective LT7 laser sensors provide ranges up to 250 m and diffuse LT7 laser sensors provide long-range background suppression up to 10 m.
In the beverage industry, date/lot codes are mandatory on all products in order to identify when and where a product was manufactured. Finding a solution that can accurately identify the bottle caps and then trigger a machine to print the date/lot codes onto the bottle is required.
WORLD-BEAM QS18 Universal Voltage sensors are mounted along a conveyor to detect the presence and position of passing paletts. These sensors can be connected to either AC or DC power, allowing them to operate in large conveyor applications already using AC power without requiring a separate power supply. In addition to the universal voltage, this sensor also has a popular 18 mm barrel shape, multiple mounting options, and a rugged IP67 housing to withstand harsh environments. Having multiple power and mounting options in a single sensor allow for a quick and easy retrofit on the line.
The lead frame of an integrated circuit moves on a U-shaped channel toward the cassette that holds multiple frames. The D10 Expert Analog/Discrete sensor detects the leading and trailing edge, to signal to the cassette that the lead frame is approaching. The sensor operates in the opposed mode, because large differences in reflectivity of frame materials make diffuse sensing impossible.
Center arm pivot irrigation systems are used throughout the Midwest to minimize water use and ensure crop health. Because the sections of the center pivot assembly have to move at different speeds, the motors moving each section must be monitored to verify each section is moving at the proper speed and time.
Banner’s RP-LS42 safety rope pulls line conveyors as a way to indicate emergencies and immediately shut down conveyors. If a rope pull is used during an emergency, it can be difficult to locate exactly where it was pulled. A K30 indicator light can be paired with the rope pulls in order to provide indication as to where the rope was pulled. This allows for quick and easy indication of where an emergency occurred, helping to return to normal operations as fast as possible.
Banner’s wireless solutions can have multiple gateways tied to respective nodes, allowing for elimination of all wires and providing flexible mounting options. The wireless structure of gateways and nodes are responsible for communicating the critical I/O throughout the facility. Even with multiple wireless products, the wireless communication system is efficient and has no cross talk interference and does not interfere with the IT department.
Banner provides sensing and industrial LED lighting solutions to help minimize carton and product damage inside a container. Banner’s QS18FF with background suppression has a fixed range up to 100 mm with an 850 microsecond response time, allowing for easy detection of the packages/cargo and ensuring the extendable conveyor does not crush cartons. Banner’s WLB32 is a cost-effective, LED lighting solution available in both AC and DC versions with a high lumen output that ensures proper illumin
To meet governmental regulations, landfill managers need to accurately monitor methane gas production, removal, venting, and burning. To accurately determine methane production levels and flow, a pressure transducer can detect both pressure and vacuum present within the methane production system.
Cartons moving on a conveyor pass between two LE550 laser sensors, measuring the width in order to sort cartons properly. The LE550 sensors are an economic solution for carton profiling. The analog output sends a signal to the PLC to deliver the carton to the correct storage location. Banner’s LE550 provides repeatability and accuracy while measuring the height, length and width of cartons. The laser sensors have an intuitive user interface, making it easy to adjust settings.
Visual indication is an easy, effective way to communicate status to keep equipment operating efficiently and increase productivity. Intensely bright beacon lights are highly visible during daylight and indicate the condition of the spreader twist locks to the operator cabin to ensure a secure lift. The beacon lights feature intense levels of light output and are very rugged and durable, making them ideal for outdoor indication applications.
Banner’s Q45 wireless call sensor communicates to a wireless DX80, signaling that forklift drivers can remove the completed pallet for shipping. This helps keep the conveyor clear, keep it moving faster and leads to more productivity. Since forklift drivers are being called to action more quickly, it allows for more productivity.
Slip rings are subject to constant movement which in turn leads to continuous maintenance in order to avoid degradation of the rotating electrical connection caused by normal wear and debris. Slip ring failure bring production to a halt, resulting in unexpected and costly downtime. The DX80 wireless radios provide a non-contact solution for transmitting the sensor signals from inside the filler bowl to the control panel. The wireless node located on the rotary filler can be battery powered thus providing power to the sensors for a wire-free installation. The DX80 wireless solution eliminates the need for slip rings, helping to decrease downtime and maintenance.
Banner’s Q30FF600 background suppression sensor confirms when a product enters the exit chute to ensure it came off the sortation system and that there isn’t a jam in the product chute. The Q30FF600 has long range sensing up to 600 mm, which is the standard width of many chutes.
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.
PresencePLUS Pro II mini cameras are set up on induction stations of the sortation system for easy inspection of all items entering the system. The vision cameras can inspect and detect packages ranging from business card size to massive boxes, as well as detect packages of varying colors. The compact mini cameras and flexible mounting options provide a simple installation without the need for alterations.
To collect snap samples quicker and avoid exposure to wastewater, use wireless technology to automatically collect snap samples and deliver the contents to the collection jug. A small pump installed at the collection site can be activated automatically, and at programmed time intervals, to extract the snap sample. A wireless signal is used to trigger the collection and to confirm a successful collection.
S18L general-purpose indicators are ideal for use in panels. Their intense light and bright indication easily communicates various machine stages, including cycle hold, cycle enable and fault, to factory floor workers. The S18L 18 mm indicator lights are available with up to three independent colors including green, red, yellow, blue, white, orange, turquoise, violet, sky blue and magenta. Customers can create customized panel solutions and clear indication systems on the factory floor. Workers can easily see the stages with highly bright LED indicator lights.
In the process of die bonding and wire bonding, lead frames are conveyed in a tall vertical cassette. To increase throughput, the cassettes are inspected to determine if a lead frame is present in each slot. Because the lead frame can be as thin as 0.1 mm, it can be difficult to sense. The VS1 convergent sensor easily senses this thin profile, as well as non-reflective plastic ball grid arrays (PBGA).
Banner’s 30 mm mount E-Stop buttons work well in this type of application because they have an illuminated base that turns from yellow to flashing red when actuated. The red flashing illumination of the E-stop button visibly alerts operators which button was pressed so they can quickly and easily fix the problem to reduce down time and only reset the button that was activated.
Banner’s EZ-ARRAY measuring light curtains detect items as small as 5 mm wide with an edge resolution of 2.5 mm, and have high excess gain for detecting opaque objects. These features allow for reliable detection and measurement of packages that pass through the light curtains. The total number of beams blocked for each pair indicates the size, which is sent to a sorter as an analog signal. A PLC then diverts each carton to the appropriate storage location.
SB12 positioning sensors are placed on multishuttles in order to confirm that product stays within the safety zone and confirms a product is positioned correctly to avoid hanging off the “safe zone.” SB12 sensors are cost effective and have cross-talk avoidance as well as light immunity, making them ideal for a warehouse environment. The compact size and easy installation makes them easy to place on multishuttle.
Applications involving such large machinery can make wiring difficult and unsafe. Fortunately, wireless solutions allow for easy transmission of distance data. Various wireless devices can be setup up between cranes so multiple cranes can service the same area. Wireless products are also offered in rugged housing making them suitable for outdoor environments. Using wireless equipment to accurately monitor the cranes prevents costly repairs or replacements.
In order to detect these chips as they move down the conveyor, powerful sensors need to rapidly and accurately count them, but there are not many sensors that are tiny enough to fit into tight, confined spaces and still have reliable, speedy detection that keeps up with the integrated circuits as they pass by. With Banner’s ultra-miniature compact Q12 sensor, counting integrated circuits on the manufacturing line is simple.
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.
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.
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.
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.
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.
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.
Detecting trucks and signalling arrival, wireless communication
Use shifts in magnetic fields to detect arrival and trigger alert
Wireless solution, remain in low-power standby mode until vehicle is detected
Outdoor truck detection for safety prevention purposes
Wireless detection at parking lot entrances
Outdoor vehicle detection in an environment not easily wired
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.
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.
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.
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. It is offered in retroreflective models with two discrete outputs (PNP) for extremely long ranges up to 250 m, making it a versatile sensor in the automotive industry.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Accidents can happen when people and mobile equipment share intersections in a factory. See how to create a controlled intersection with multicolor lights.
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.
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.
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.
Washdown environment, IP69K ratings required
High-speed labeler processing 800 bottles per minute
Track bottles as they move through the rotary filter.
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.
A car travels along a conveyor into a hazardous area guarded by an SGS Series Safety Grid System. As the car approaches, the SGS Grid is temporarily muted to allow the car to pass without stopping the conveyor. While the Grid is muted, there is the risk that a worker will attempt to enter the hazardous area through the interlocked breakaway guard, putting the worker in a dangerous situation and presenting the possibility that the worker will be struck by the moving car.
Banner’s Type 4 EZ-Screen with a muting is ideal for depalletizer stations with robots because the screens ensure safety standards are maintained while allowing for a free flow of pallets, increasing throughput. The muting allows for a pallet skid to be transferred without shutting down the conveyor or robot cell, helping optimize product flow throughout the distribution center. There is a timing function set at a constant speed that allows for a continuous flow of pallets.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
The bakery’s multi-staged baking process begins with mixing, kneading and fermentation and completes with proofing, baking and cooling. At each stage, experienced bakers perform quality checks for appearance, texture, size and weight. Loaves that do not meet the company’s standards are rejected for consumer sales. The company needed to build-in system capabilities to help them better manage their resources and maintain quality standards.
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.
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.
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.
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.
A US producer of authentic Mexican foods, such as tortillas and tostadas, strives to provide the best-tasting and freshest products for its consumers. In order to achieve this goal, consistency on the packaging line is key. The company was looking for a way to eliminate inconsistencies in their tortillas. Because they did not have a way to continuously monitor dough thickness on the production line, the dough nips often turned out either too high or too low, resulting in irregular tortilla sizes and weights. If a package of tortillas is under weight, it must be scrapped. In order to help eliminate waste and improve product consistency, the company worked with Banner to find a monitoring solution.
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.
Accurately detecting bonding wire breakage to reduce downtime.
A leading manufacturer of conveying equipment designs and builds high-quality, low-cost conveyance solutions. The pallet equipment they develop is expected to reliably convey, palletize and depalletize thousands of pallets and unit loads annually. This equipment must be able to sense a wide range of different pallet types and sizes to ensure the proper packing and unpacking of pallets and avoid line slow-downs, pallet crashes and collapses.
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.
In the manufacturer's facility, operators manually insert and remove metal parts from the die press. When complete, the parts are sent into a bin via a metal chute. In order to prevent die crash (having double parts in the press at once) the customer needed a sensor that could detect various parts on the chute and send a signal to the control system, indicating that the press is free and allowing the operator to perform another stroke. The solution needed to be installed without cutting slots in the chute sides or mounting sensors at the end of the chute, which could create catch points for traveling parts.
A leading manufacturer of labeling equipment offers high-speed shrink sleeve label applicators designed to process 800 bottles per minute. To maximize the machine’s performance potential, the company wanted to install sensors capable of consistent detection and output for high-speed bottling.
A recent industry switch from polypropene (PP) to polyethylene terephthalate (PETE) bottles prompted a leading US mail-order facility to re-evaluate their fulfillment process. With over 2,000 red LED sensors to be replaced, the facility turned to Banner for a solution.
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.
A high-volume brewery needed a solution capable of detecting spreader washers on the vent tubes as well as loose or missing tubes. However, the movement of the rotary filler and the wet washdown environment made close proximity deployments difficult and the range required for a remote solution could compromise inspection reliability.
A municipality has over 30 farm fields irrigated with gray water using pivot irrigation systems. Local regulations prohibit the irrigation system from spraying over roads and ditches. The customer needs a solution that can reliably control the water flow to the end nozzle based on predetermined location coordinates.
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.
The Gateway, or wireless network controller, monitors the water level inside the water tank. When the water level drops, a Node installed with the reservoir pumps uses its outputs to cycle the pumps on or off. A series of Nodes monitors the amount of water flowing into each orchard. A 1 Watt Data Radio connected to the Gateway transmits the data to a mobile asset or a centralized control center for data processing and billing.
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.
Blind spot object detection, alerting operators with time to respond
Reduce vehicle congestion, wireless monitoring
Wireless vehicle detection at a quick serve restaurant drive-thru.
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.
• Precise location detection</br> • High-speed conveyor</br> • Customer specific product</br>
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.
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.
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.
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.
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.
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.
Hermes Abrasives requested lighting to improve inspection capabilities of abrasive products.
A customer requested brilliant illumination of multiple work stations
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.
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.
Customer requested lighting fixture to aid in monitoring the welding process
A machinery company needed a sensor able to consistently detect clear PET bottles at multiple points.
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.
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.
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.