Material Handling: Conveying and Sortation

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Conveying and Sortation

A single distribution center may process millions of products and parcels in a single day. The heart of any facility is the equipment used to move these items from location to location. The speed with which a parcel travels through the center and the accuracy with which it is delivered is critical to the effectiveness of the system.

Conveyors and sortation systems are the most common way to move and distribute parcels through a facility and to their intended destinations. Banner sensors, vision sensors, sensing arrays, barcode readers, LED lights and indicators play critical roles in supporting this equipment. Our products regulate the cycling of motors on a conveyor, help maintain the required space between products, identify and track parcels as they travel through the system, and verify that a parcel has arrived at its intended destination. Products from Banner help the systems at the heart of the facility operate more efficiently and effectively.

 

Applications

Barcode Reading
Barcode Reading

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.

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Exit Chute Jam Indication
Exit Chute Jam Indication

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.

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Presence/Absence Item Detection
Presence/Absence Item Detection

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.

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Emergency Stop Buttons on a Conveyor
Emergency Stop Buttons on a Conveyor

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.

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Carton Dimensioning
Carton Dimensioning

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.

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Emergency Indication on Conveyors
Emergency Indication on Conveyors

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.

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QS18 Series
QS18 Series

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

DS18 Series
DS18 Series

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

Safety Rope Pull Switches for Stop Control
Safety Rope Pull Switches for Stop Control

Rope pull emergency stop switches, when used with steel wire rope, provide emergency stop actuation for conveyors and large machinery.

30 mm Mount Emergency Stop Buttons
30 mm Mount Emergency Stop Buttons

Patented 30 mm mounting base enables easy installation and hookup with no assembly, individual wiring or additional enclosure required.

Linear Array Backlights
Linear Array Backlights

Banner Engineering Linear Array Lights provide maintenance-free LED illumination of large objects from far away.

Measuring Arrays: EZ-ARRAY Series
Measuring Arrays: EZ-ARRAY Series

EZ-ARRAY excels at high-speed, precise process monitoring and inspection, profiling and web-guiding applications with quick and simple installation. Applications include edge and center-guiding, loop tension control, hole sizing, parts counting and on-the-fly product sizing and profiling. Closely spaced infrared beams detect objects as small as 5 mm wide edge resolution is 2.5 mm. Controller functionality is built into the receiver, so basic setup requires no controller, software, or PC. IO-Link, Modbus-RTU, and RS-485 models are available.

Small and Flat Object Detection: LX Series
Small and Flat Object Detection: LX Series

The LX Part-Sensing Arrays provides wide area detection used for detecting small parts on conveyors, part ejection verification and leading edge detection.

TL70 Tower Lights - Wireless
TL70 Tower Lights - Wireless

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.