All Material Handling Solutions

  1. Detailed Inspection on a Sortation Conveyor

    In large distribution facilities, sortation trays deliver products to the proper bin for correct shipment. Before sorting can begin, each tray needs to be empty so that items can be placed on the conveyor and sent to the next location. The 5mp VE Smart Camera recognizes very fine levels of detail and can detect items of almost any size, confirming the presence or absence of items on the trays.

  2. Order Fulfillment: Wide Shelf

    Each wide shelf is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor in retroreflective mode, which has a range of up to 2 m. The PVD lights up on the bin from which the worker should select the map to ship.

  3. Bin Picking for Order Fulfillment

    In a book packing warehouse, the rack above each carton of books is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor. A worker fills orders by selecting the quantity of each book specified on the packing slip. To make it easier for the worker to find the cartons from which to pick books, the PVDs above those cartons are illuminated. The PVD detects the workers hand in the carton to verify that the title was picked.

  4. Tracking Package Location through Conveyor Roller Gaps

    • Precise location detection • High-speed conveyor • Customer specific product

  5. 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.

  6. Tracking of Received Goods

    Banner’s TCNM linear barcode scanner quickly and easily detects up to 10 linear barcodes on packages, helping maintain accountability and an efficient flow of packages throughout a distribution center. The TCNM linear barcode scanner is ready to scan right out of the box with SMART TEACH, providing scan rates of 500 to 1,000 scans per second. The linear barcode scanner can read barcodes in ranges from 40 to 600 mm.

  7. Long-Range Position Detection

    In a warehouse, the time-of-flight L-GAGE LT7 laser sensor gauges the position of a retrieval shuttle as far as 250 m away from the sensor.

  8. Delivery Truck Detection at an Outdoor Loading Dock

    Automated solution to help alert workers of a delivery truck's arrival through the use of shifts in magnetic fields.

  9. Loading Dock Sensor Monitoring and Indication of Truck's Presence

    Sensor solution to signal the presence of a truck at a dock door with bright illumination.

  10. Delivery Vehicle Detection with Indication in Warehouse

    Vehicle detection at loading docks is complicated because sensing solutions are exposed to the elements and need to recognize a wide variety of surfaces. Rugged ultrasonic sensors work well to accurately detect the surfaces of delivery vehicles regardless of the material. Pairing with bright LED indication creates unmistakable operator guidance.

  11. High-Quality LED Lighting for Workstations

    Banner’s WLB32 Industrial Light Bar is ideal for workstations. With a Hi/Lo/Off switch, operators are able to control the lighting level and are able to switch the LED light bar off when they are done. The WLB32 provides workers high brightness with even light output and enables numerous tasks in a workstation, including working on a computer.

  12. Highly Bright Illumination in Workstations

    Banner’s WLS28 Work Light Strips with ON/OFF switches provide an energy-efficient solution for illuminating work areas and enclosure interiors with intense, long-lasting light. These LED lighting strips provide even, extremely bright illumination, and can easily fit in limited space setups. The work lights can be plugged into any local power source for simple operation.

  13. Low-Bay LED Lighting

    The heavy-duty, energy-saving WLB92 from Banner Engineering provides an extremely bright lighting solution that provides consistent lighting across a warehouse. Since the LED factory light is so bright and gives a uniform output, fewer lights are needed in total, helping reduce the overall cost of lights and installation time.

  14. Extendable Reach Conveyor

    Banner provides sensing and industrial LED lighting solutions to help minimize carton and product damage inside a container. Banner’s QS18FF with background suppression has a fixed range up to 100 mm with an 850 microsecond response time, allowing for easy detection of the packages/cargo and ensuring the extendable conveyor does not crush cartons. Banner’s WLB32 is a cost-effective, LED lighting solution available in both AC and DC versions with a high lumen output that ensures proper illumin

  15. Shuttle Tote Positioning

    SB12 positioning sensors are placed on multishuttles in order to confirm that product stays within the safety zone and confirms a product is positioned correctly to avoid hanging off the “safe zone.” SB12 sensors are cost effective and have cross-talk avoidance as well as light immunity, making them ideal for a warehouse environment. The compact size and easy installation makes them easy to place on multishuttle.

  16. Wireless Forklift Signaling

    Banner’s Q45 wireless call sensor communicates to a wireless DX80, signaling that forklift drivers can remove the completed pallet for shipping. This helps keep the conveyor clear, keep it moving faster and leads to more productivity. Since forklift drivers are being called to action more quickly, it allows for more productivity.

  17. Full Tote Indication and Verification

    In order to properly identify and use visual management, a sensor is triggered when the bag is full and then sends a signal to a K50 touch button to light red, which represents a full tote. The K50 touch visually shows operators the bag needs to be removed and changed with an empty one. In order to show the bag is ready for more packages, the operator presses the ergonomic K50 touch button, changing it back to green to show the bag is ready for more packages.

  18. 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.

  19. 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.

  20. Sortation Auto Induction Station

    S18-2 retroreflective sensors provide long-range, effective sensing along an auto-induct conveyor station. Polarized sensors can help with shiny surfaces by reducing false triggers. The S18-2 retroreflective sensors are cost-effective sensors with a barrel mount style, making them easy to install along a conveyor for verification purposes and are available in retroreflective, thur-beam, diffuse or fixed-field models.

  21. Stacker Crane Positioning

    Banner’s time-of-flight LT7 laser sensors provide long-distance ranges up to 250 m with a visible red laser spot for easy alignment. Depending on range needed, a diffuse or retroreflective time-of-flight laser sensor can be used. Retroreflective LT7 laser sensors provide ranges up to 250 m and diffuse LT7 laser sensors provide long-range background suppression up to 10 m.

  22. 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.

  23. Parcel Collision Avoidance

    Banner’s DS18 sensor coupled with a zone control modules offers a cost-effective solution that gives an output and shows a change in state for optimal flow of products. This helps prevent box collisions and stops the zone so contents of packages are preserved.

  24. Accurate Pallet Detection

    Banner’s PVD100 is a custom-made solution that accurately detects pallets without adjustments, even when features are inconsistent. This easy-to-use, versatile light screen has a wide beam pattern, making alignment simple. With a compact design, it can easily be embedded into a machine or directly on the line. The PVD100 light screen sensing solution has a detection height of 100 mm and a scanning range of 2 m. It has highly visible red and green LED lighting to display operation and indicate

  25. 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.

  26. Traffic Control at Loading Docks

    EZ-LIGHT Traffic Lights are mounted at each bay to visually signal to drivers when they have permission to back into the loading dock. The lights are preassembled, with up to three indicators and three colors in one housing, making them cost effective and easy to install. Traffic Lights are an ideal solution for outdoor applications, with intense levels of light output and included sun shields.

  27. Replacing Cables on a Transport Cart

    Transport carts typically use a conductor cable for operation, which breaks over time and causes production delays and increased maintenance costs. Controlling transport carts wirelessly reduces these issues.

  28. Pallet Transfer Safeguarding

    Due to the dangers associated with a full pallet transfer, horizontal area guarding is needed in order to maximize productivity of packaging while protecting operators from the hazardous motion of a machine.

  29. Detecting Pallets with Irregular Loads

    An ultrasonic sensor will provide reliable pallet detection. Ultrasonic sensors emit sound waves and “listen” for the return echo of the sound wave bouncing off the target. The sensor can be taught a reliable background, in this case the conveyor, and will listen for sound waves returning from the conveyor. Any object getting between the sensor and the conveyor will be detected, causing the output to switch.

  30. 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.

  31. Carton Sizing

    Cartons moving on a conveyor pass between three pairs of EZ-ARRAY measuring 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.

  32. Conveyor Jam Detection

    In the event of packages or totes coming around the corner of a conveyor getting caught, a WORLD-BEAM QS18 Universal Voltage sensor positioned at a bend will communicate to an alarm or PLC that an object has become lodged in front of it, alerting employees to the presence of a jam.

  33. Baggage Handling

    WORLD-BEAM QS18 Universal Voltage sensors mounted along an airline conveyor detect the presence and position of passing luggage. QS18 Universal Voltage sensors can be connected to either AC or DC power, allowing them to operate in large conveyor applications already using AC power without requiring a separate power supply. The robust, compact housing and multiple mounting options add to the versatility of WORLD-BEAM QS18 Universal Voltage sensors.

  34. Retrofitting for Pallet Detection

    WORLD-BEAM QS18 Universal Voltage sensors are mounted along a conveyor to detect the presence and position of passing paletts. These sensors can be connected to either AC or DC power, allowing them to operate in large conveyor applications already using AC power without requiring a separate power supply. In addition to the universal voltage, this sensor also has a popular 18 mm barrel shape, multiple mounting options, and a rugged IP67 housing to withstand harsh environments. Having multiple power and mounting options in a single sensor allow for a quick and easy retrofit on the line.

  35. Mail Sorting for Size

    Three QS18 opposed mode sensors above the roller conveyor detect any passing object, triggering the horizontal QS18 sensor. Letters pass below the horizontal QS18 undetected and are diverted to the letter conveyor. Parcels are detected and continue forward.

  36. Load Station Pallet Detection

    The WOLD-BEAM Q20 diffuse sensor is positioned to detect the presence of a pallet. Once the pallet is in place, an output signals the robot to begin loading.

  37. Facility Function Monitoring

    Banner’s wireless solutions can have multiple gateways tied to respective nodes, allowing for elimination of all wires and providing flexible mounting options. The wireless structure of gateways and nodes are responsible for communicating the critical I/O throughout the facility. Even with multiple wireless products, the wireless communication system is efficient and has no cross talk interference and does not interfere with the IT department.

  38. 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.

  39. Objects on a Conveyor

    The WORLD-BEAM Q20 diffuse sensors are positioned above a conveyor line in an array pattern to detect the presence of objects on a high speed conveyor.

  40. Detecting Items On an AC-Powered Conveyor

    WORLD-BEAM QS18 Universal Voltage sensors can be connected to either AC or DC power, allowing them to operate in large conveyor applications already using AC power without requiring a separate power supply. The robust, compact housing and multiple mounting options add to the versatility of WORLD-BEAM QS18 Universal Voltage sensors.