All Automotive Solutions

  1. Detect Installed Glass on Automobile

    • Detect the presence of a moonroof • Extended range capabilities • Automobile assembly line

  2. 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.

  3. High-Quality LED Lights Improve Quality Inspection

    The most important part of lighting up an automotive environment for inspection purposes is to find a light source that provides consistent, extremely bright light. The energy-efficient WLB92 is easy to install and gives a consistent, bright light with minimal glare to inspect automotive parts. Increased lighting can improve worker productivity and reduce eye strain.

  4. 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.

  5. 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.

  6. Operator Guidance Solution

    A Henshaw customer manufactures drivetrain and powertrain systems for the automotive industry. The company had experienced productivity losses due to errors in the assembly of transmission valve bodies. Henshaw was tasked with developing a system that would reduce errors and improve the assembly process.

  7. Run Bar Provides Operator Guidance

    A leading machine manufacturer builds workstations designed for accurate, timely and cost-effective battery cell assembly. A value added component of the workstations is an operator guidance device that does three jobs: enables assembly processes to start and stop, indicates parts to be picked and installed, and completely stops line operation if emergencies occur. When it became too costly for the OEM to construct and mount these devices themselves, they turned to Banner to craft an all-inclusive solution. To honor the time line requirements of their customer—a major tier two battery supplier—the OEM needed the solution in eight weeks.

  8. Engine Block Positioning

    Banner’s L-GAGE LH Laser Displacement Sensor is ideal for applications where exact positioning of a part is crucial. The L-GAGE LH Series consistently looks at dark targets on micron levels. Banner’s laser displacement sensor is extremely accurate for precise positioning applications, including engine block positioning. The sensor can take measurements on virtually any surface, such as cast iron or aluminum alloys, which are often used for the manufacturing of engine blocks.

  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. Part Removal Verification in Automotive Assembly

    In an automotive assembly plant, temporary pins—called grenade pins—are used to attach some parts temporarily. To make sure the grenade pins are removed, the inspection station includes a container for the pins that is equipped with an EZ-LIGHT PVA pick-to-light sensor.

  11. Rubber Washer Detection on Engine Block

    Banner’s Q4X versatile laser sensor is ideal for presence/absence detection even in challenging applications with small height changes such as confirming a small black target is present on a shiny metal part. The washers should be present in the cast aluminum engine block, and if the Q4X detects a slight height difference, even as small as 1 mm, it will send a signal to alert operators a rubber washer is missing or there are multiple washers present. The Q4X can detect duplicate rubber washers with its unique windowing capability while in foreground suppression mode.

  12. 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.

  13. 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.

  14. UV Barcodes for Traceability

    Before shipping to the brand assembler, a supplier of auto visors needs to verify that Data Matrix UV barcodes have been printed on each visor’s safety label. The customer turned to Banner to read invisible 2D Data Matrix barcode and send data via Ethernet IP to a PLC for traceability/error proofing.

  15. Manual Load Weld Cell

    Banner’s EZ-SCREEN® series safety light curtain system is a well established solution for the harsh requirements of welding equipment. With the ability to cascade (series connect) multiple segments together, configurations such as this horizontal/ vertical pair are easily implemented with standard hardware (no master/slave models).

  16. Gate Monitoring with a Hinged Interlock

    A car travels along a conveyor into a hazardous area guarded by an EZ-SCREEN Grid. As the car approaches, the EZ-SCREEN 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.

  17. 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.

  18. 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.

  19. Measuring Movement Range

    After comparing performance and cost, the company chose L-GAGE® LE550 laser sensors. LE550 sensors can detect changes as slight as 1 mm at a meter away, but at nearly half the price of the sensors they replaced. Utilizing linear array technology and laser triangulation, the LE550s provide exceptional linearity, repeatability and resolution across their entire 100 mm - 1000 mm operating range. LE550 sensors feature a small spot size and visible beam for easy alignment.

  20. Sheet Metal Thickness Measurement

    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.

  21. Detecting a Line of Adhesive on a Vehicle Door Panel

    A VE Series Smart Camera, configured to use the bead tool, inspects each door panel for the presence and consistency of adhesive. The camera has a wide field of view and a 2 MP imager capable of detecting even slight inconsistencies in the amount of adhesive applied.

  22. 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.

  23. 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.

  24. Thread Hole Detection

    Conventional sensors can often have difficulty detecting the presence of threads. The WORLD-BEAM QS30's narrow laser beam can detect whether a hole in the manifold is threaded from a distance of up to 800 mm.

  25. Drilled Holes Inspection

    This application uses an iVu Series sensor configured for an Area inspection. When holes are punched, the sensor evaluates all the holes to make sure that they are present and correctly sized. If any are not, the sensor sends a fail output to the line where the part is rejected.

  26. Bearing Inspection

    The solution involves using an iVu Series sensor configured for a Match inspection to ensure that all the bearings are present for each component that includes the bearing assembly. If the sensor detects one or more missing bearings, it sends a fail output to the line, and the component is rejected.

  27. Engine Block Part-In-Place Detection

    Banner’s LE550 laser sensor is ideal for part-in-place verification processes. It is reliable, and extremely accurate for small part-in-place verification from long distances. The LE550 measures for 3 mm thickness using the digital output, ensuring that the retaining clip is present and the engine block is in the correct place.

  28. Automotive Welding Tip Inspection

    The R55F high color resolution sensor checks whether the tips on a welder are within specifications, so the part being manufactured also is within specifications. In this harsh environment, the color contrast sensor uses glass fibers, for enhanced durability and heat resistance.

  29. Part-in-Place Verification

    The WORLD-BEAM QS18 adjustable field background suppression sensor is an excellent choice for this part-in-place application, requiring a three-inch scanning distance. With the combination of high-gain characteristics, sharp adjustable cutoff and a forgiving visible red light beam this sensor ensures longevity in this harsh environment.

  30. Long-Range Inspection in Automotive Assembly

    As vehicles move forward on an automotive assembly line, an L-GAGE LT7 time-of-flight laser sensor is directed inside the sun roof to verify that the car seat has been installed and is in the correct position. 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.

  31. Automotive Weld Nut Inspection

    After a robot inserts multiple weld nuts in an automotive component, a worker places the part onto an inspection station equipped with two PresencePLUS P4 OMNI vision sensors. Improperly inserted weld nuts could be missing, upside down, or tipped to one side. The PresencePLUS P4 OMNI inspects to see that the weld nuts are present, correctly oriented and not leaning.The vision camera compensates for part-to-part movement and can inspect from a long distance.

  32. Automotive Fuse Box Inspection

    A PresencePLUS COLOR Pro vision sensor inspects color-coded fuses in a fuse box to verify that each fuse is in the correct location.

  33. Automotive Duct Inspection

    After a vacuum mass-airflow test of an automotive duct, a shuttle moves the PresencePLUS Pro into position above an open end of the duct. The PresencePLUS Pro verifies that a temperature sensor is still in place inside the duct and is undamaged.

  34. Plastic Injection Short Shot Detection

    A high-resolution PresencePLUS P4 OMNI 1.3 mounted above a production line inspects steering wheel components after they are molded. The P4 OMNI looks for areas with excess material or too little material.

  35. Automotive Handle Color Inspection

    A PresencePLUS P4 COLOR OMNI vision sensor detects interior door handles that are the wrong color for the vehicles being assembled. An on-axis light, attached with specialized brackets, provides even, diffused illumination to reduce glare.

  36. Temperature Sensor Detects Defrost Wires

    An automotive manufacturer was rejecting a supplier’s shipment of rear window assemblies due to faulty defroster grids. The supplier’s existing test procedure measured current draw across the entire heating system to detect an overall failure, but it could not detect the subtle impact of a single heating wire being broken. The window supplier partnered with a Michigan-based machine automation company to create a better test fixture—one that can verify each defrost wire heats to specification prior to shipping.

  37. 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.

  38. Detecting Parts Ejected from Die

    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.

  39. 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.

  40. Window Tint Verification

    Banner’s DF-G1 light receiver sensor differentiates between windows with or without tint based on how much external light passes through the glass. The DF-G1 self-contained device has a simple push button set-up for easy adjustment along the conveyor. An intuitive user display allows for immediate sensor feedback.

  41. Light Receiver Detects Broad Spectrum of Lights

    Banner’s DF-G1 fiber optic light receiver is a unique, cost-effective product that is designed to be placed directly in test equipment to ensure lights are functioning correctly. With the same intuitive dual display and programming interface as other DF-G1 models, the light receiver can be integrated and interfaced with assembly and test equipment control systems for pass/fail inspection.

  42. Optical Touch Button (OTB) and Emergency-Stop Operator Station

    With the all-in-one unit, the emergency stop pushbutton combined with an OTB provides a simplified operator station for manufacturing lines that does not require wiring or additional enclosures. Banner’s 30 mm mount E-Stop buttons work well in this type of application. Their illuminated base turns from yellow to flashing red when actuated, making them compliant with emergency stop requirements. The proximity of the emergency stop button to the OTB means workers can quickly and easily actuate

  43. 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.

  44. 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.

  45. Rotating Equipment Monitoring

    In a number of automotive manufacturing processes, rotary tables are used to index parts into various automatic and manual work stations. In many cases, it is necessary to use sensors to verify that parts are present, properly placed, or correctly processed before indexing. Historically, the solution of using slip rings to allow sensor power and signals to be hardwired to the control system has often proven to be costly and unreliable. An alternative solution that allows more sensor signals to be processed while increasing the reliability is needed.

  46. Die Protection in Tire Manufacturing

    The dies in tire presses suffer costly damage if the press tries to stamp the tread into an unstamped, or green, tire of the wrong size. To direct each tire to the correct press, Banner’s PresencePLUS P4 BCR 1.3 vision sensors sort green tires based on identifying information in the bar code printed on a label on the tire’s bead. In this application, the green tires moving on a conveyor pass below a fixture on which six BCR 1.3 vision sensors are mounted.

  47. 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.

  48. Wireless Reduces Downtime

    A producer of stainless steel and special alloys supplies billets, blooms and ingots to the metal casting industry. During production, articulating robots are used to handle magnesium billets. Proximity switches located on the end effectors of the robots communicate status information from the grippers to a control panel. Robotic cables had been used to connect the proximity switches to the control panel. Environmental challenges and the motion of the robot compromised the integrity of the cables. Breaks were quite frequent and production had to be halted for repair and replacement, pushing up costs and driving down productivity.