汽車業解決方案

Temperature Sensor Detects Defrost Wires [Success Story]

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.

Motor Temperature Monitoring and Control with a Wireless Network

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

Equipment Monitoring from a Supervisor's Station

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

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

Call for Pickup from an Assembly Station to an AGV

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

Warning Indication where Obstructions Limit Visibility

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

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

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

Status Indication on Driverless Vehicles [Success Story]

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.

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.

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.

監控液壓動力裝置

輕鬆監控液壓動力裝置和其他液壓機械的壓力、電流、油溫和電機振動/溫度。Snap Signal 產品連接各種類型的感測器並將其訊號轉換為 Modbus 資料以進行實時狀態監控。

Monitor Leaks in Your Critical Applications

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

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

Detect Installed Glass on Automobile

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

Manual Load Weld Cell

Banner的EZ-SCREEN®系列安全光幕系統是針對焊接設備的苛刻的惡劣環境要求而發展出的完整的解決方案。藉由將多個設備串接（串聯）的能力，可以使用標準配件（非主/從模式）將安全光幕以水平/垂直的方式安裝與設定。

彎管機邊界安全防護

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

Area and Gate Guarding on Automotive Assembly Line

汽車沿著輸送帶行進到由EZ-SCREEN光幕保護的危險區域。在汽車接近時，EZ-SCREEN光幕暫時被遮蔽，允許汽車通過而不停止輸送帶。在光幕被遮蔽時，工人可能會通過互鎖的分離安全防護設備嘗試進入危險區域，這會使工人處於危險境地，並導致工人可能被移動的汽車撞到。

可追溯性紫外光條碼

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.

視覺感測器讀取 QR 碼

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.

讀取汽車零部件上的 DPM 條碼

Direct part mark (DPM) codes can be small, complex, and difficult to distinguish from the material they are etched into.

操作指導解決方案

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.

配戴手套進行組裝作業

Banner的定距式K50指示燈檢測戴有手套的手，用來辨別操作人員在組裝過程中是否選擇了正確的零組件。之後，K50指示燈的邏輯功能可以透過從綠色更改為黃色（也可以選擇其他顏色，以配合製造商的選擇偏好）來通知操作人員其已經正確拾取。K50檢測深色手套的能力對於精益製造過程尤其重要，在此過程中，員工通常配戴深色手套。

小箱子的零件拾取指示

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.

長型料箱拾取指示燈

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.

多產品組裝站光導指示系統

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.

大型工作站的光導引套組

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

LED Lights Illuminate Control Cabinet

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.

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.

使用綠光LED工作燈偵測表面瑕疵

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

高品質 LED 工作燈有助於改善品管效率

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

High-Quality LED Lighting for Conveyor Illumination

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

Assembly Timer Indication at Automotive Assembly Station

In automotive manufacturing, maximizing efficiency is crucial in order to meet production goals. Delays at assembly stations can hold up processes later down the line, leading to costly wasted time and missed production targets. The TL50 Pro tower light helps assemblers meet expected cycle times and support overall takt time requirements.

雙輸出狀態指示

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

Inspecting Small Connectors [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.

量測鈑金厚度

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

Sensors to Measure Movement Range

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

精確量測曲軸徑向跳動

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

Ply Orientation Inspection

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

Run Bar提供操作人員指示

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.

引擎汽缸體定位

Banner的L-GAGE LH雷射位移感測器非常適用於對零組件的精確定位有很高要求的應用。L-GAGE LH系列可以持續以微米級別檢測深色目標物。Banner的雷射位移感測器非常準確，適合精確的定位應用，包括引擎汽缸定位。感測器可以在幾乎任何經常用於製造引擎氣缸的表面上進行測量，例如鑄鐵或鋁合金。

汽車組裝線上的零件拆卸檢驗

在汽車組裝廠會用臨時別針暫時固定一些零件。為了確保臨時別針都有被正確移除，裝有EZ-LIGHT PVA拾取燈感測器的檢測站都有一個回收別針的容器。

引擎汽缸上的橡膠墊圈偵測

Banner的Q4X多功能雷射感測器很適合進行存在/不存在偵測，即使是高度變化微小的挑戰應用中，例如，確認閃亮金屬零件上存在的小型黑色目標物。墊圈應存在於鑄鋁引擎汽缸體中，如果Q4X偵測到輕微的高度差，即使小至 1 毫米，也會發出信號，警告操作者橡膠墊圈不存在，或是有放入了多個墊圈。Q4X可以在前景消除模式下，透過設定檢測區間來偵測重複橡膠墊圈。

車門板上的塗膠檢測

VE系列智能型視覺感測器使用塗膠檢測工具, 可以檢測門板上的黏膠以確保塗膠的有無以及多寡VE視覺感測器有寬廣的視野以及2百萬畫素的鏡頭, 可以檢測出每片門板上塗膠的微小變化

偵測黑色門板上的黑色零部件

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.

沖壓金屬零部件的多點檢查

為了驗證金屬小零部件上存在預期的孔數，可以為多個偵測區域(ROI)設定具有多點檢測功能的iVu Plus TG影像感測器，以確保孔存在並且打孔位置正確。在設定區域檢測時，iVu將掃描沖壓零部件上的多個點，以驗證是否存在某個特征或關注的特徵。

螺絲孔偵測

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.

鑽孔檢測

此應用使用為區域檢測而設定的iVu系列感測器。在沖孔時，感測器評估所有孔，以確保它們存在並且尺寸正確。如果有的孔不存在，則感測器會將故障輸出發送管線，零部件將在管線上被剔除。

軸承檢測

此解決方案包括使用為配對檢測而設定的iVu系列感測器，以確保對於包括軸承總成的每個組件，所有軸承均存在。如果感測器檢測到缺少一個或多個軸承，則會將故障輸出訊號發送給生產線，並且組件被剔除。

引擎氣缸零部件就位偵測

Banner的LE550雷射感測器是零部件就位驗證過程的理想選擇。它很可靠，並且對於長距離的小型零部件就位驗證非常準確。LE550採用數位輸出來測量3 mm厚度，確保固定夾存在並且引擎氣缸位於正確的位置。

汽車焊嘴檢測

R55F高解析度感測器檢查焊機的尖嘴是否在規格範圍內，以確保所製造的零部件也在規格範圍內。在此苛刻的環境中，顏色對比感測器使用玻璃光纖，以提高耐用性和耐熱性。

零部件就位驗證

WORLD-BEAM QS18可調現場背景消除感測器是零部件就位應用的理想選擇，它需要三英寸的掃描距離。憑藉高增益特性、敏銳的可調截止值和寬大的可見紅燈光束的組合，該感測器確保了在這種惡劣環境下具有較長壽命。

汽車組裝長距離檢測

隨著車輛在汽車組裝線上前進，L-GAGE LT7雷射感測器被引導到汽車天窗內，以驗證汽車座椅已經安裝並處於正確的位置。它提供了具有兩個輸出(PNP)的鏡面反射型式，以提供可達250米的超長工作距離，這使其成為汽車行業的多功能感測器。

汽車焊接螺母檢測

在機器手臂在汽車部件中插入多個焊接螺母後，工人會將零組件放置在配備有兩台PresencePLUS P4 OMNI視覺感測器的檢測站中。不正確插入的焊接螺母可能是有遺失、顛倒或傾斜到一側的情形。PresencePLUS P4 OMNI檢測確保焊接螺母存在、正確定向和傾斜度。視覺Camera補償零組件間的移動，並可以從遠距離檢測整個流程。

汽車保險絲盒檢測

PresencePLUS COLOR Pro視覺感測器檢查保險絲盒中的顏色編碼保險絲，以驗證每根保險絲是否在正確的位置。

汽車進氣歧管檢測

在汽車的進氣歧管的真空-氣流測試之後，自走車會將PresencePLUS Pro移動到歧管開口端上方的位置。PresencePLUS Pro會確認溫度感測器仍然在導管內的位置，沒有損壞。

射出機成型檢測

安裝在生產線上方的高解析度PresencePLUS P4 OMNI 1.3在方向盤部件模製後對其進行檢測。P4 OMNI尋找材料過多或過少的區域。

汽車把手顏色檢測

PresencePLUS P4 COLOR OMNI視覺感測器檢測車門內把手，確保對於正在組裝的車輛不會有錯誤顏色的把手。帶有專門的支架的同軸燈提供均勻的正面照明，以減少眩光。

工業捲線機零缺陷標準[成功案例分享]

一家成功的特種工業紗線製造商為汽車、航空航天、軍事和復合材料行業製造玻璃纖維和玻璃絲線產品。為了保持高標準并盡可能降低產品回報，他們建立了零產品缺陷的目標。為了實現這一目標，公司需要一個自動化絲線檢測系統。

車門板部件顏色檢測

iVu顏色感測器識別車門板上各個裝飾件的RGB 值，並通過工業乙太網連接將此資訊傳送至PLC。

汽車座椅檢測

Q5X驗證深色背景上是否存在深色部件，以及車輛座椅和不同顏色部件。

確認衝壓機上的金屬板

Q5X 感測器可在惡劣環境下確認是否存在亮面目標物並確定其位置。

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.

購物中心將車輛引導至有空位的停車場[成功案例]

一個大型零售停車中心用無線感測器減少車輛堵塞，顧客不滿。

充電站的電動車偵測

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.

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所有汽車業解決方案