Automotive: Final Assembly

Auto Final Assembly Hero

Final Assembly in Auto Manufacturing

Designed and developed to perform reliably in tough industrial and manufacturing environments, products and solutions from Banner Engineering help auto manufacturers ensure assembly quality, increase productivity and process efficiency, while reducing operational expenses and production downtime.

Banner solutions are used extensively throughout final assembly areas at auto manufacturing facilities around the world. Our sensors and vision sensors are used for inspection, vehicle detection, model ID and material handling applications. LED indicators and tower lights satisfy visual management needs in final assembly. Our light-guided assembly products improve output and assembly accuracy. LED lights from Banner provide brilliant illumination for work areas and offer years of no maintenance operation, energy efficiency and cost savings. SureCross wireless solutions are ideal for for Andon and ‘Call For’ systems.

Applications

Moonroof Detection
Moonroof Detection

The detection of clear glass is a common challenge in the automobile industry. The optical beam of traditional photoelectric sensors will burn through clear material, making sensing results unreliable. The solution must be capable of detecting the clear glass of the moonroof. The U-GAGE T30UX Series Ultrasonic Sensor uses pulses of ultrasonic energy, which reflect off the target and back to the sensor, to reliably detect clear materials.

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Long Bin Pick-to-Light
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.

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Improving Production with Pick-to-Light Systems
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.

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Kitting Operation with Gloves
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.

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Long-Range Inspection in Automotive Assembly
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.

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70 mm Modular Tower Lights: TL70 Series
70 mm Modular Tower Lights: TL70 Series

TL70 Modular Tower Light is bigger, brighter and can be ordered as modular segments or pre-assembled. Wireless TL70 Tower Lights combine Banner's popular Tower Light family with its reliable, field proven, SureCross wireless architecture.

50mm Domed Indicators: K50L Series
50mm Domed Indicators: K50L Series

Our most popular indicator light. The 50 mm general-purpose indicator is available in both AC and DC supply voltage.

Q45 Wireless Sensors
Q45 Wireless Sensors

The Sure Cross® Q45 is the first self-contained wireless standard photoelectric solution for the most challenging control and monitoring needs. Easily add a scalable wireless sensor network to improve efficiency by monitoring and coordinating multiple machines and processes without pulling cables.

50 mm Optical Pick-to-Light Sensors: K50 Series
50 mm Optical Pick-to-Light Sensors: K50 Series

Provides improved ways to install a pick-to-light system with industry standard Modbus RTU protocol for communication.

50 mm Illuminated Touch Buttons: K50 Series
50 mm Illuminated Touch Buttons: K50 Series

K50 Series touch buttons combine a large, bright indicator with solid-state, touch-activated switching capability, ideal for lean manufacturing and bin-picking operations.

One Piece Part Verification Array Pick-to-Lights: PVD Series
One Piece Part Verification Array Pick-to-Lights: PVD Series

PVD Pick-to-Light sensors are compact, one-piece solutions useful in many part assembly, pick-to-light and error-proofing applications.

VE Series Smart Camera
VE Series Smart Camera

Combine powerful inspection tools and capabilities with ease of use to maximize inspection uptime and facilitate rapid implementation.

Long Range Ultrasonic Sensors: QT50U Series
Long Range Ultrasonic Sensors: QT50U Series

Senses extended range of up to 8 m. Features a completely sealed, shock-resistant housing that is ideal for monitoring levels of liquids as well as solids. Uses a narrow sensing beam to detect targets at long range within confined areas such as a storage tank without interference from the tank walls.

Wireless M-GAGE Node
Wireless M-GAGE Node

FlexPower Node with internal battery designed for vehicle detection.

QS18 Series
QS18 Series

Universal housing design with 18 mm threaded lens; an ideal replacement for hundreds of other sensor styles.

LED Lights Illuminate Control Cabinet
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.

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Superior Light Distribution with LEDs
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.

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Temperature Sensor Detects Defrost Wires
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.

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Vision Sensor to Read QR Codes
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.

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