All Assembly and Robotics Solutions

  1. 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.

  2. 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.

  3. High-Quality LED Lighting for Automation Illumination

    Banner’s WLB32 is an LED industrial light bar with easy mounting options, such as snap clips and a choice of magnetic or angle brackets. LED lights can be easily be cascaded to properly illuminate the manufacturing line. Banner’s LED lighting is an ideal replacement for conventional fluorescent lighting.

  4. Superior Light Distribution with LEDs

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

  5. 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.

  6. logo with r symbol

    • Bright illumination of work station • Energy and cost savings • Long-lasting LED lights • Easily installed into existing equipment systems

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  21. 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.

  22. Assembly Error-Proofing

    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.

  23. 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.

  24. 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.

  25. Robotic Cell Industrial Bar Code Inspection

    Since it can be difficult and expensive to stop robotic operations to configure and monitor the bar code inspection process, it's a good idea to install an iVu Bar Code Reader with Remote Display. The Remote Display can be mounted up to 16 m (50 feet) away from the sensor to enable machine operators to easily configure and remotely monitor or troubleshoot the inspection process while the robot is in operation.

  26. 2D Stamped Industrial Bar Code Verification

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

  27. 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.

  28. 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.

  29. 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.

  30. 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.

  31. 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.

  32. 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.

  33. Area Guarding for Robotic Cells

    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.

  34. 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.

  35. 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.

  36. Inspecting Small Connectors

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

  37. 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.

  38. 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.

  39. 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.

  40. 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.

  41. Part Orientation

    In the application shown, nuts exiting a vibratory feeder bowl are transported to the next step in the assembly process. It is essential that the correct side of the nut faces up so they can be used efficiently in the process. The iVu SeriesTG Image Sensor possesses the inspection capabilities necessary for determining part orientation. The sensor, when configured for a Match inspection, will compare each nut to a reference to determine if there is a match.

  42. 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.

  43. 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.

  44. 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.

  45. Remote Monitoring Calculates Machine Run Time

    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.

  46. Streamlining Call for Parts or Service

    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.

  47. Communication in a Busy Manufacturing Site

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

  48. 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.

  49. 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.

  50. 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.

  51. 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.

  52. 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.

  53. 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.

  54. 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.

  55. 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.

  56. 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.

  57. 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.

  58. 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.

  59. Vision Sensor to Read QR Codes

    Prior to installation, engines and transmissions are coupled together on the assembly line. A worker using a hand held bar code reader scans the QR code on each transmission. The codes are small, have minimal quiet zones and are dense with embedded information. Additionally, the bar code readers have a limited range. Combined, these factors made scanning the QR codes difficult, adding time to the assembly process and diverting labor resources.

  60. 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.

  61. 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.

  62. Presence Detection on Rotating Lathe Turret

    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.