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  1. Banner’s WLB72 Inspection is a very bright LED luminaire that features an even light output for a no glare glow. This LED light bar uses advanced LED technology to provide a high-quality and maintenance free industrial lighting solution. The unique lensing provides a dark-to-light-to-dark transition on a vehicle surface suitable for detailed inspection tasks.

  2. 3 Apr 2019

    A laser measurement solution enables high-speed package sorting in order fulfillment applications and helps drives failure rates down—ultimately saving costs and maximizing profits.

  3. Barcode position can change with the location of each box on a conveyor and the height of the boxes can vary. An ABR 7000 barcode reader decodes multiple 1D and 2D barcodes over a large area in a single inspection, regardless of position or orientation.

  4. Barcodes used to track packaged produce through the supply chain contain important product information that must be verified at multiple points during packaging. An ABR 3000 barcode reader ensures that the barcode on each package is present and correct.

  5. Direct part mark (DPM) codes can be small, complex, and difficult to distinguish from the material they are etched into. The ABR 7000 barcode reader is available in models specifically designed to solve challenging low-contrast and DPM applications like this.

  6. To optimize efficiency and output, the progress of multiple FOUPs in single wafer deposition machine must be closely monitored. Staff work in close proximity to these machines and prolonged exposure to bright light from tower lights can cause eye strain, leading to physical and mental fatigue. Keep reading to learn how TL30 Basic tower lights solve this application.

  7. Crankshaft runout measurements must be monitored continuously to ensure that they meet tolerance requirements. Learn how LM Series laser measurement sensors solve this difficult application.

  8. A precise measurement solution is required to ensure that integrated circuit (IC) chips are present and oriented correctly in nests. Learn how the LM laser measurement sensor solves this application.

  9. Remote monitoring enables increased visibility into the performance and efficiency of machines, processes, and people.

  10. Predictive maintenance enables users to more accurately anticipate when machine maintenance will be needed based on real-time data from the machines themselves.

  11. Remote monitoring capabilities provide data for OEE calculations, making it easier for manufacturers to identify and remedy causes of waste within their facilities.

  12. Remotely monitoring tank level can help improve efficiencies and increase productivity and profitability.

  13. IIoT technologies enable better communication throughout the factory and streamline processes for machines and people alike.

  14. Sensors detect the leading edge of pallets, polybags, blister packs, envelopes, tubes, and a wide range of difficult to detect targets.

  15. There are many advantages of IO-Link including reduced wiring, increased data availability, remote monitoring, simple device replacement, and advanced diagnostics.

  16. Banner’s wireless vibration and temperature sensor measures RMS velocity, in inches per second or millimeters per second, and temperature. Mounting it as close as possible to the bearings enables you to monitor the machine’s health by detecting increases in vibration and temperature. It is easy to mount using the standard bracket, the magnetic bracket or two sided thermal transfer mounting tape.

  17. FlexPower Nodes equipped with thermocouple or RTD sensors were mounted near the monitored motors. The sensor data is sent to a Gateway installed in a central control location. The temperature set point can be established to meet the applications requirements and then provide a discrete output from the Gateway. When predetermined temperature levels are detected, the red light of a stack light connected to a Gateway lights up, alerting personnel that maintenance is required.

  18. Wireless products enable predictive maintenance in the port industry. Motors and gearboxes on cranes are prone to high vibration and temperature which can cause them to degrade. Predictive maintenance allows employees to interfere and solve problems before they completely fail and cause unplanned downtime and lost profit.

  19. Wireless monitoring of rotating parts on coal conveyors throughout a large port allows operators to utilize predictive maintenance to prevent failure and save money while reducing downtime.

  20. 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.

  21. Using K50U ultrasonic sensors and Q45U wireless nodes paired to a DXM100 wireless controller, we can develop a wireless monitoring system for multiple tank level measurements that is easy to set up, interpret the results, and monitor locally through a cloud-based system.

  22. The EPA has placed restrictions on the use of many fumigants citing a correlation between their use and ozone depletion. As an alternative, a large-scale flour mill performs three to four thermal remediations per year to eradicate flour beetles. The temperature inside the mill is brought up to 122° F (50° C). This is done gradually to minimize equipment and building strain caused by heat expansion.

  23. Instead of installing I/O transmission cabling, use a 10 to 30V dc powered SureCross Node and a Banner T-GAGE temperature sensor. When using host control systems, the SureCross Gateway transmits the temperature to the plant control room using a digital output related to temperature setpoints within the sensor. The motor is powered down or up based on these temperatures. When using a Gateway Pro as the wireless master device, the data ca be logged and alerts sent out to notify maintenance personnel when a motor is performing outside expected parameters.

  24. To allow for quicker, more frequent, and more efficient scanning of target valve population tailpipe temperatures, a series of FlexPower Thermocouple Nodes and FlexPower Battery Supply Modules are installed. Temperature measurements of the valves and pipes are measured and wirelessly transmitted to a DXM100 Wireless Controller mounted in a central location. The DXM100 gathers the data and transfers the data to a SCADA system that monitors and graphically displays the temperature data.

  25. Banner’s DX99 Nodes offer solutions for monitoring the temperature of motor bearings using thermocouples or RTDs. Because these are low power sensors and radios, a battery life of up to three years is possible. The Node sends temperature data wirelessly back to a central control location for logging and analysis. When the bearing temperature rises unexpectedly, maintenance can be scheduled before any motors burn out or equipment is damaged. It is likely this temperature data would not be monit

  26. Soil moisture and air temperature sensing ranges are typically under a mile, but the Site Survey tested the signal out to two miles. With the MultiHop Radio and its antenna installed very low to the ground, the Master Radio was installed with a large omnidirectional antenna to maximize the communication range.

  27. A SureCross FlexPower™ Node with internal battery directly connected to a temperature and humidity sensor can provide these measurements without costly conduit or cabling, eliminating the need to manually collect data from multiple sensor locations. IP67 electronics and a variety of filter options make this product suited for the wide temperature and humidity ranges encountered in a greenhouse.

  28. T-GAGE M18T Series Temperature Sensors are passive, non-contacting, temperature-based devices designed to detect objects that are hotter or colder than the ambient condition, and then activate an output. In this application, the T-GAGE temperature sensor will detect the presence or absence of hot glue on the flaps of the package. If the hot glue is present, the process will continue and the package will be sealed. If it’s absent, the output will trigger a process to apply the hot glue.

  29. A semiconductor fab needs to monitor temperature, relative humidity, and oxygen levels at multiple points within their processing plant, along a 2 kilometer long process piping system. They require a solution that monitors temperature, relative humidity, and oxygen levels, provides a location for the monitoring points, and collects all data to a central point and interfaces with their SCADA system. The solution needs to create an efficient, safe work environment for all employees. With over 2 kilometers of underground tunnel piping systems, installing cable to each monitoring location is cost prohibitive.

  30. A large cabinet maker needs to monitor and control the temperature and humidity throughout many rooms in a large production facility. Manual environmental readings of the entire plant were conducted periodically throughout the week. These manual readings only provided a snapshot of information and gathering the data took more than three hours. The customer did not have real-time, accurate information that could be used to control the plant environment. Manually collecting this information and controlling the fan system was timeconsuming and resulted in errors that damaged wood in storage, work in progress, and finished cabinets.

  31. Clinical labs need to process samples quickly to keep throughput high and any lag during testing procedures would disrupt workflow. LED lightings, such as the K50L2, works as machine status indication so that the lab operators can process fix errors, handle samples, and collect results in a timely manner.

  32. • Expand available data beyond local indication • Gather information necessary to react quickly • Drive efficiency improvements based on data previously unavailable

  33. • Increase efficiency using a wireless call-for-parts/service/pickup system • Connect up to 18 work stations with six forklifts/Hi-Los • Resolve critical issues quickly without disrupting workflow

  34. • Provide at-a-glance machine status indication • Send machine status information to a wide range of devices • Alert staff and supervisors of critical conditions via text message or email

  35. • Restock assembly stations before components run out without overstocking • Provide real-time communication between assemblers and the forklift operators who supply them • Monitor delivery efficiency

  36. • Remove completed pallets from assembly stations quickly • Enable direct communication from assembly stations to AGVs • Improve process efficiency using turnaround time data to

  37. • Provide instant visual communication across a busy plant floor • Collect machine status and other data to calculate Overall Equipment Effectiveness (OEE) • Alert staff to critical conditions via text message or email

  38. • Identify small problems before they become major issues that impact machine performance and uptime • Access environmental data from a remote location • Notify operators of critical conditions via text message or email

  39. • Identify machine problems before they cause serious damage or unplanned downtime • Alert staff of changes in condition via text message or email • Provide at-a-glance local indication of machine status

  40. • Minimize production errors by providing clear guidance for assembly • Reconfigure and move assembly stations without rewiring • Improve production efficiency and better utilize facility space

  41. Monitoring production inputs and outputs provides machine operators and managers with critical data about their processes and equipment and can help them identify and resolve problems on the production line more quickly.

  42. The K50L domed 50 mm indicator light works well for status indication on autonomous shuttle buses. The buses operate on short distances in outdoor environments that exposed the bus technology to a variety of weather conditions. The rugged K50L indicators are rated IP67 and IP69K to withstand water ingress in the harsh environment.

  43. S22 Pro Series touch buttons and indicators simplify control panel design and improve operator experience and performance. Pro Editor software expands the built-in display capabilities available with the S22 Pro Series, enabling custom displays.

  44. K50 Pro touch buttons with IO-Link communication display takt time within workers' sightlines so that the assembly pace stays on track and meets production goals.

  45. Performance Series all-in-one wireless pressure sensors make it easy to monitor pressure levels in large and complex systems from any network-enabled location.

  46. Detecting clear and reflective objects are some of the most challenging sensor applications. Light can burn through a target or be reflected away erratically, making accurate detection difficult.

  47. Dark objects are difficult to detect since they reflect very little light back to the sensor. In addition, black on black targets (low contrast between target and background) are especially challenging.

  48. In packaging, targets often contain vibrant, multicolored graphics of varying reflectivity. Such varied targets can be difficult to detect reliably, especially when there are many color transitions.

  49. Many applications, such as registration mark detection and high-speed part counting, require sensors with response speeds fast enough to reliably detect fast moving targets.

  50. There are many advantages of an IO-Link system including reduced wiring, increased data availability, remote monitoring, simple device replacement, and advanced diagnostics.

  51. Products with higher IP ratings are designed to work better in harsh environments where standard sensors would easily get damaged and produce false readings.

  52. Clear, thermoformed plastic containers, trays and clamshells are used to package a wide variety of products. Packagers must be able to detect the leading edge.

  53. Detect clear glass and PET plastic bottles with various shapes and sizes. Washdown environment, IP69K ratings.

  54. The Q5X laser sensor reliably detects when the staging area is clear of bottles and the system is ready for the next layer of containers, despite the transparency of the bottles and unstable signal.

  55. Sensor solutions to detect translucent bottles in a range of shapes, sizes, colors and contours in a high-speed air conveyance system, identifying gaps.

  56. Sensor solutions to verify packaging and count on conveyor. Foil and film packaging such as tea bags, multiple colors on packaging material.

  57. Sensor solutions to detect clear vials in pharmaceutical and medical manufacturing where a hygenic sensor is needed in a harsh chemical washdown environment.

  58. Sensor solutions to detect clear glass jars to be filled with food in a strict sanitary environment where frequent, high-pressure washdowns and IP69K ratings.

  59. Sensor solutions to detect bottle types with varying frequent in product changovers. High-speed labeler processing 800 bottles per minute, high temps.

  60. Sensor solutions to detect accumulations to regulate line pressure where bottles vary in size, shape, color, and translucence and there is not a reflector.

  61. Sensor solutions to detect reflective food wrappers such as Mylar with conveyor belt presence verification, utilizing foreground suppression.

  62. Using a sensor in clear object sensing mode to ensure proper staging of plastic trays during denesting process.

  63. Sensor solutions to count translucent and reflective glass vials in high-speed processes requiring quick response times and challenging light conditions.

  64. Sensor solutions to monitor a conveyor to ensure there are no stuck bottles when bottles are clear plastic in a large sensing area.

  65. Sensor solutions to count containers that are made of clear plastic when containers are various shapes and have ridges.

  66. Sensor solutions to count rings on a conveyor belt where the rings have a very reflective surface and a cylindrical shape.

  67. Sensor solutions to detect perforations on continuous web of translucent plastic bags where high-speed equipment is used and a large-volume of material process.

  68. Sensor solutions to detect glass vials filled with transparent liquid in an aseptic, stainless steel environment with rounded bottles.

  69. Sensor solutions to detect the presence of a moonroof on an automobile assembly line where extended range capabilities are required.

  70. Sensor solutions to recognize clear glass vials and bottles in high-speed application with precise leading edge detection.

  71. Sensor solutions to detect a low contrast edges of glass on conveyor in a clean industrial environment where equipment is regularly exposed to high temperatures

  72. Sensor solutions to detect translucent bottles filled with clear liquid with a long bottling line with numerous areas to monitor.

  73. Sensor solutions to detect plastic bottles varying in color and translucence where a high-speed system requires fast response times. Accurate sorting.

  74. Sensor solutions to detect I.V. bags, glass vials, syringes and pharmaceutical packaging. Fill level inspections ensure product content amounts are accurate.

  75. Detect translucent bottles varying by size, shape, color, and faceting. Large scale system of monitoring in multiple locations, quick clearance of tipped bottle.

  76. Sensor solutions to detect small installation areas with multiple deployments on the line. Accurate detection of shiny cans supports smooth product flow.

  77. Sensor solutions to detect bottle types vary in size, shape, color, translucence, and material. Equipment is regularly exposed to harsh washdown.

  78. Sensor solutions to detect bottle types vary by size, shape, color, contours, and translucence on a rinser where equipment is regularly exposed to washdowns.

  79. Learn how the Q4X detects clear plastic trays at hopper and filling station in the food industry.

  80. Hamer, LLC is a Minnesota-based manufacturer of automated packaging equipment for a wide variety of applications and world-wide customers. From pet food to pellet fuels, Hamer machinery packages products in a variety of weights and sizes at speeds up to 60 bags per minute. A vital component of Hamer’s equipment is registration mark sensing—the ability to detect marks on packaging as it passes at high speeds. When a mark is detected, the equipment cuts the packaging at the designated location, eliminating waste and ensuring each bag is consistent.

  81. Banner’s Q3X versatile, rugged laser contrast sensor is ideal for detecting registration marks. With a range up to 300 mm, the Q3X has a tight laser spot able to detect a small white registration mark reliably. When the Q3X detects the white registration mark, the intensity readout increases and a discrete output is triggered, indicating the white registration mark is present and it is the correct package going down the line.

  82. Banner’s R58 high-speed, low-contrast expert registration sensor detects subtle registration marks on the labels as they pass at high speed—ensuring the label is cut at precisely the right moment for correct label placement. To accommodate frequent changeovers, the sensor is designed with LED color options—which automatically change depending which color best optimizes contrast.

  83. Banner’s R58 Expert registration mark high color resolution sensor is a high-performing sensor with an ultra fast 10 kHz switching frequency that quickly detects splices and other defects that are otherwise hard to detect. The high sensitivity of the R58 Expert detects the inconspicuous splice in a roll of paper to ensure the printer skips over the splice during the press process.

  84. As empty tubes go down the manufacturing line, a visible light sensor can verify a toothpaste tube’s registration mark before being filled and sealed. Banner’s high-speed R58 visible light color contrast sensor is an extremely powerful sensor for registration mark applications and can easily read marks on high-gloss and low-contrast surfaces, detecting contrasts as low as two percent over a wide range of colors.

  85. Banner’s R58 Expert registration mark color contrast sensor is a high-performing sensor with an ultra fast 10 kHz switching frequency that quickly detects registration marks, which is ideal for tube positioning applications. Even with a high-gloss surface or a low-contrast situation, the R58 Expert can easily detect the registration mark on a filled tube to determine how it should be oriented.

  86. Banner Engineering’s R58B Expert registration mark sensor confirms the registration mark’s position on the web. This allows the machine to make minor infeed adjustments to ensure the cut is properly placed and all labels are consistent and complete. If the labels are incorrectly cut they need to be removed from the bottling line creating costly downtime and waste. A quick and easy-to-use sensor is needed to dramatically improve throughput.

  87. Industrial safety controllers provide an interface between safety devices and the machines and processes those devices monitor for an easy-to-use safety control solution.

  88. The point of operation on a machine is where the work is performed. Because workers are in close proximity to pinch points, safety is critical.

  89. Perimeter guarding applications require guarding on multiple sides of the machine. Meanwhile, access guarding protects an access point into the hazardous area.

  90. Operators must be able to safely start (initiate) machine processes as well as safely stop them in an emergency.

  91. Safeguarding palletizer machines present many challenges to keep personnel safe and maintain efficient production. The new SGS Safety Grid with muting arm bar kit protects the dangerous robotic machinery while allowing boxes to pass through the Grids without stopping production. The muting arms can recognize if anything other than a box passes through the Grids and will trigger a machine stop on the palletizer.

  92. Safeguarding palletizer machines can be difficult because bottles are under a lot of pressure and can contain corrosive liquids such as soda or juice. Hygienic enclosures protect light curtains from corrosive liquids, meet sanitary requirements, and do not affect the performance of the sensor.

  93. Safety light screens on a meat slicer protect operators from sharp blades while in operation. The environment is harsh and frequently exposed to chemical washdowns. The EZ-SCREEN LS with hygienic enclosure keeps personnel safe while preventing water and chemical damage to the light screen.

  94. Algus Packaging Inc. is a leader in the heat seal and thermoform packaging industry. They design, develop and manufacture high-performance sealing machines, thermoformed packaging and offer full service contract packaging. The machinery and services offered by Algus provide their customers with the ability to change and grow as business needs dictate, now and in the future.

  95. 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.

  96. 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.

  97. Banner’s Type 4 EZ-Screen with a muting is ideal for depalletizer stations with robots because the screens ensure safety standards are maintained while allowing for a free flow of pallets, increasing throughput. The muting allows for a pallet skid to be transferred without shutting down the conveyor or robot cell, helping optimize product flow throughout the distribution center. There is a timing function set at a constant speed that allows for a continuous flow of pallets.

  98. 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.

  99. 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.

  100. 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.

  101. The solution requires the sensor to mount snugly within a machine opening, with continual end-to-end sensing that leaves no gaps. This enables the light screen to be located a minimum distance from the machine hazard point, using minimal floor space (which reduces the reach for the operator), and eliminating snag and aesthetic issues. At 28 mm x 26 mm (1.1" x 1"), Banner's EZ-SCREEN LP safety light screen is incredibly compact and can mount in tight spaces.

  102. 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).

  103. The Type 2 EZ-SCREEN safety light screen protects hands and fingers from being bumped, bruised, or pinched by the moving parts of a carousel.

  104. The Type 2 EZ-SCREEN safety light screen guards the opening to a chip shooter, which has moving parts that can cause painful but usually temporary injuries.

  105. Two angled mirrors bounce the beam from the emitter to the receiver of the EZ-SCREEN safety light screen Point, so one Point does the work of two.

  106. At both open sides of a robotic work cell, a pair of EZ-SCREEN safety light screens are linked—or cascaded—in an L-shaped configuration to guard the access point both vertically (reducing separation distance) and horizontally (providing continual sensing). Up to four pairs of EZ-SCREEN light screens can be connected.

  107. Widely spaced SGS safety grid platform light screen economically protects the perimeter of a work area. The grid is far enough from the hazard that motion has time to stop if a person or object passes through the grid.

  108. To guard the perimeter of a tube bender work cell, two free-standing corner mirrors are set up to reflect the sensing field from the emitter, around the perimeter’s corners, to the receiver. Using corner mirrors is an economical way to make use of the range of an EZ-SCREEN safety light screen by guarding multiple sides of an area with one emitter/receiver pair.

  109. The EZ-SCREEN safety light screen uses fixed blanking and reduced resolution (also called floating blanking) to allow flat boxes to enter the machine. Fixed blanking allows the safety light screen to ignore the boxes, and reduced resolution lets it ignore slight variations in the box height. If the supply of boxes runs out, leaving the fixed blanked area clear, the EZ-SCREEN ligted curtain stops the machine so the operator can safely refill the carton supply.

  110. 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.

  111. 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.

  112. A car travels along a conveyor into a hazardous area guarded by an SGS Series Safety Grid System. As the car approaches, the SGS 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.

  113. In this application, machine operators require access to the wafer carrier station. The EZ-SCREEN ESD safety light curtain system is configured to safeguard the process and operator using emitters, receivers and mirrors to enclose three sides of the station. Safety light curtains allow quicker, easier access than physical barriers while preventing machine movement if the operator reaches into the hazardous zone.

  114. 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.

  115. The EZ-Screen LPs Type 4 Safety Light screens guard the operators of a depalletizer from the motion of the sweep bar. To guard individuals from the sweep bar, a 14mm resolution between beams prevents access and injury. If an individual or item breaks the beams of the EZ-Screen, the sweeping motion will stop to prevent harm. The low-profile design of the light curtains allows for easy installation along a machine and does not require a PC or additional equipment for setup.

  116. 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.

  117. The design of our EZ-SCREEN muting light curtains allows for a free flow of pallets while keeping the dangerous area guarded to shut down the machines if any workers were to enter the space. The muting option on the EZ-SCREENs lets a pallet skid be transferred without the need to shut down or reset the machine, which would usually slow down the production line. The muting option is necessary in the beverage industry for certain assembly procedures to run smoothly.

  118. In this application, a hazardous work cell is completely guarded to prevent personnel from entering the area. In order to allow parts and material to flow into the area efficiently, entry and exit zones will be left open. The EZ-SCREEN safety light screen is positioned in front of these zones and will stop the hazardous motion of the machine if an operator tries to reach or enter through these areas.

  119. Safeguarding areas around the palletizers and stretch wrappers can prove to be difficult because it involves multiple hazards. A scalable safety controller can help manage hazards related to the palletizer and stretch wrapper while ensuring efficient safeguarding processes.

  120. Learn how magnet switches protect operators from the harmful interior of a heat sealer.

  121. An LS Series safety light curtain with a mute arm kit in T-configuration combined with an XS26 Series safety controller is an easy-to-implement solution that protects staff from potential hazards without disrupting the flow of pallets to the depalletizer.

  122. An SLC4 safety light curtain safeguards a small access point on a compact machine without disrupting access or operation

  123. A robotic weld cell is protected on multiple sides by hard guarding. Between work cycles operators must be able to access the weld cell to retrieve completed work pieces and load new material. Used to safeguard access points to the weld cell, an SX5-B safety laser scanner can increase machine uptime and productivity.

  124. Pallet transfer conveyors are used to move heavy loads to the shipping area. Both the pallets and the conveyor pose risks for accident and injury and must be safeguarded. An SX5-B safety laser scanners safeguards the loading and unloading stations on the conveyor and enables a continuous flow of pallets through the system.

  125. Learn how SI-RF Series safety switches can be used to monitor multiple guard doors, ensuring the highest levels of safety, and making it easy to identify and resolve issues.

  126. An SC10 Series safety controller replaces the functionality of three safety relays with one compact, cost-effective device offering intuitive operation and advanced capabilities.

  127. Recalls happen, and when they do, it is critical that manufacturers respond quickly by identifying affected products and issuing a timely recall to mitigate damages.

  128. Food packaging facilities verify product barcodes at multiple points so they can quickly identify and isolate product with quality issues and ensure a safe food chain.

  129. Pharmaceutical traceability is required to eliminate counterfeits, ensure patient safety, and comply with regulations.

  130. Work in Process (WIP) tracking refers to tracking each item in production throughout the entire manufacturing process to ensure efficiency, accuracy, and traceability.

  131. Direct Part Marks (DPM) are codes that are etched or printed directly onto a part's surface. Due to poor contrast, they can be extremely challenging to read.

  132. A leading pharmaceutical manufacturer produces a diverse range of medical products. Many of their products are individually packaged in sealed pouches. Each pouch has a 1D barcode encoding the product’s identification. Before the product can be shipped the company must validate that the correct barcode is on the pouch and verify that the package is correctly aligned for heat sealing.

  133. 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.

  134. Banner’s TCNM linear barcode scanner is recommended for scanning and validating the barcodes. It is able to decode over a dozen commonly used linear barcode symbols helping maintain an efficient flow of bottles along the production line. Utilizing the TCNM linear sensor allows for an automated way to confirm the correct product in real time.

  135. 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.

  136. 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.

  137. Banner’s iVu Plus BCR Gen 2 with remote display offers an easy to use solution for reading barcodes to ensure correct labels have been applied. The iVu Plus BCR Gen 2 models provide both a fine mode, for reading smaller barcodes that require full resolution, and coarse mode, for applications where speed is critical.

  138. Medicine bottle labels include both a linear and a 2-dimensional barcode. The PresencePLUS P4 BCR reads both types simultaneously to verify that they are correct.

  139. The PresencePLUS P4 BCR industrial barcode scanner reads and verifies the small 2D bar code affixed to a component of a cell phone.

  140. The Pro, equipped wtih a barcode reader tool, enhances compliance with federal requirements for identifying and tracking pharmaceutical products.

  141. An iVu BCR with UV ring light is an ideal solution for detecting barcodes in a low contrast situation. The iVu is coupled with UV illumination for an all-in-one solution that improves contrast on clear labels so bar codes are easily detected.

  142. A PresencePLUS P4 BCR industrial barcode reader detects and verifies the subtle 2D barcode that was stamped into a metal gear so it can be tracked through production and in the field.

  143. The iVu BCR is used in many mail applications to help direct mailers from multiple smaller runs as they are combined into larger ones.

  144. It can be difficult and expensive to stop robotic operations to configure and monitor the barcode inspection process. An iVu BCR barcode reader with remote display can be mounted up to 16 m (50 feet) away from the sensor for remote monitoring and troubleshooting while the robot is in operation.

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

  146. A part is tracked using both a linear and a 2-dimensional barcode. The high-resolution PresencePLUS P4 BCR 1.3 reads both types simultaneously to verify that they are correct.

  147. Shipping containers are often labeled with barcodes in order to more easily identify which product is present and ready to be shipped. A sensing solution needs to be present to confirm that the final, shrink-wrapped product is labeled correctly and matches the content inside.

  148. iVu Plus BCR Gen 2 with 25 mm Micro Lens replaces hand held barcode readers to collect data from dense, difficult-to-read QR codes on vehicle transmissions. A WL50S high-intensity LED spot light illuminates the target area.

  149. Pick-to-light systems support lean manufacturing initiatives by reducing the risk of human error in production and assembly processes.

  150. Put-to-light solutions improve the efficiency and accuracy of stocking and replenishment activities and can help prevent downtime by reducing delays due to misplaced or incorrect parts.

  151. Light-guided kitting and sequencing solutions allow operators to focus on building high-quality products while maintaining efficiency.

  152. Quick, accurate picking increases customer satisfaction by ensuring that customers receive the correct order in a timely manner.

  153. 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.

  154. 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.

  155. Banner’s K50 Optical Pick-to-Light series is a compact, self-contained, three color indicator with integral sensor. Green typically indicates which part to pick, and when the internal sensor detects the hand, the indicator changes to yellow to confirm the task is complete. An optional third message is to display red for a mispick.

  156. The system controller issues an instruction to pick an item from a particular location. The controller turns on the PVA’s job lights at the specified location. The job lights go off when an item from that location is removed. If multiple items are required from one location, the job light stays on until the correct number of items are removed. The bright light of the EZ-LIGHT PVA pick-to-light sensor makes it possible to see which part to pick from a distance, saving time.

  157. A pair of EZ-LIGHT PVA pick-to-light sensors are mounted to a rack on either side of a bin. In response to a signal from a process controller, the PVA illuminates to show the assembler which part to pick next. When the assembler's hand enters and leaves the bin, the controller recognizes that the part is picked and lights up the PVA for the next bin in the pick sequence.

  158. The PVL provides 100% reliability over a large area and can be mounted directly to the racking profile. The PVL can also be mounted in a vertical or horizontal orientation to suite application needs. This versatility allows for a quick set up and quick and efficient processes.

  159. Several technologies and solutions are available for bin-picking applications for error-proofing processes. Light arrays prompt the operator for part selection with integral job lights, then reliably sense retrieval of the part, using an array of visible red or infrared sensing beams located in front of the bin.

  160. 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.

  161. 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.

  162. 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.

  163. 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.

  164. 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.

  165. 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.

  166. 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.

  167. 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.

  168. 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.

  169. PTL110 pick-to-light devices on a multiproduct assembly station are a highly effective way to prevent errors and speed up build time. The optical sensors on PTL devices detect hands as they pass by, confirming that a pick was made.

  170. Manual kit building at large stations can be time-consuming and subject to human error, especially if storage racks are difficult to navigate. The PTL110 series pick-to-lights are scalable for large systems and highly versatile to complete numerous tasks.

  171. 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.

  172. 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.

  173. 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.

  174. 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.

  175. Push-button EZ-LIGHT K50 pick-to-light sensors on a rack of parts light up to indicate which parts to pick. After picking a part, the worker pushes the button on the indicator light to verify that the pick is complete.

  176. Learn how a golf equipment manufacturer recently used PTL110 pick-to-light devices to simplify and accelerate their final product assembly and order fulfillment processes.

  177. Read more to learn how the Pick-to-Light Solutions Kit improved pick sequences and ensured a high level of quality assurance at mutiproduct assembly workstations.

  178. Well-lit machines are easier to monitor, troubleshoot, and maintain. Heavy duty LED lights are built-to-last in harsh environments and provide years of bright illumination.

  179. Proper lighting reduces the risk of errors during assembly and inspection tasks, saving time and costs. Good lighting also improves worker ergonomics and reduces eye strain.

  180. Compact LED lighting can help reduce errors and speed up maintenance tasks in confined spaces like equipment cabinets and other enclosures.

  181. Visual inspection of parts and components helps manufacturers identify issues early to minimize wasted time and costs. In these applications, the right lighting is a must.

  182. An EZ-STATUS device includes both white and colored LEDs. The device can perform both task lighting and status indication functions with a single unit.

  183. 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.

  184. Banner’s WLS28 Work Light Strips provide numerous energy-efficient solutions for illuminating work areas and enclosure interiors with intense, long-lasting and durable cool white light. These LED lighting strips not only provide even, extremely bright cabinet illumination, but they also conveniently fit in the enclosure and can be plugged into any local power source.

  185. 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.

  186. Illumination during photolithography processes is challenging because white light contains a percentage of blue wavelengths, which negatively affect photosensitive materials. The WLS15 strip lights switch between two colors for safe use during photolithography.

  187. Placing WLS27 Multicolor LED Strip Lights with EZ-STATUS above PCB assembly machines provides area lighting and status indication with one rugged and versatile light. Any changes in machine status cause the WLS27 to switch from illumination to indication and cover the entire machine with the corresponding color. This type of indication allows operators to focus on the task at hand without missing changes in machine status.

  188. Machine lighting inside of automated clinical labs helps operators see and access the samples and equipment being used inside. These types of environments can be difficult on traditional lights because of the reagents and chemicals used during testing and cleaning. The WLS28-2 is rated IP69K to withstand chemicals and washdowns.

  189. Determining a lighting solution for the CNC machine is simple with Banner’s LED heavy-duty machine light, which provides enhanced chemical and thermal resistance in tough environments. The ultra-bright light is oil, chemical and water resistant with IP68, IP68g and IP69K ratings, making it an ideal choice for many industrial lighting applications, including the CNC washdown environment.

  190. Banner’s WLS28 LED Light Strips allow operators to identify frozen dinners that have not properly entered a carton and fix the problem with minimal downtime. Their long-lasting and durable cool white light means they’re an energy-efficient solution for illuminating the inside of a cartoner. IP69K rated, they can handle frequent machine wash down procedures.

  191. Accidents can happen when people and mobile equipment share intersections in a factory. See how to create a controlled intersection with multicolor lights.

  192. Lighting inside of paper drying machines is helpful during maintenance and general operation of the paper production line, but illumination is difficult because of the high heat in the machine and the wet environment. The WLH60 high temperature LED light can withstand heats as high as 100° C and is rated IP67, IP68G, and IP69K for water, oil, and chemical resistance.

  193. Learn how green LED task lights enhance visibility of surface imperfections on manufacturing materials.

  194. Automotive inspection requires consistent, bright light with minimal glare to inspect automotive parts. Increased lighting can improve worker productivity and reduce eye strain.

  195. Liquid-dosage pharmaceutical product packaging inspections involve minute human visual inspections, making it important to have bright and highly uniform illumination.

  196. High visibility is critical during inspection of product in flexographic printing because the lighting assists in monitoring machine performance. The HLS27 LED Strip Light works well near flexography printing machines because they are designed to work safely in Division 2 hazardous locations. The bright light illuminates printing functions to assist visual inspection.

  197. 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.

  198. 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.

  199. The energy-efficient WLB72 Basic is bright, easy-to-install, and cost-effective for robotic work cell lighting.

  200. WLS27 LED strip lights provide brilliant, even illumination in difficult environments like this. Each light is protected against environmental challenges and corrosion by a shatterproof, water-resistant polycarbonate shell. A redundant sealing method prevents water ingress to achieve IEC IP66, IP67, and IP69K ratings. These cost-effective LED light strips will provide vivid, low-power, maintenance-free illumination throughout their 50,000 hour or more lifespan.

  201. The company wanted a cost effective lighting solution that would offer brilliant illumination on multiple work stations on large product testing machinery.

  202. 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.

  203. 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.

  204. Banner’s WLS27 are rugged LED strip lights specifically developed to provide brilliant, even illumination in challenging environments and compact spaces. They have a space-saving, aerodynamic design, are fully encapsulated in a protective shell, and come in a broad range of illumination color options. Machine designers can install WLS27 LED strip lights wherever they are best suited to illuminate a work area without making costly or time consuming modifications to the lights.

  205. Finding a high-intensity, ultra-bright lighting solution for manufacturing can be challenging. Since multiple lights are required to properly illuminate areas on a conveyor, a simple mounting option to connect lights together is needed.

  206. The WLS27 Pro with IO-Link is one of two new models of the WLS27 Pro series strip light. It now includes programmable RGBW LEDs for use in indication, illumination, and inspection applications. Learn how the WLS27 Pro with IO-Link provided operators the necessary information and illumination to decrease product changeover times and maximize productivity.

  207. The WLS27 Pro with discrete control and configured by Banner’s Pro Editor software is one of two new models of the WLS27 Pro series strip light. It now includes programmable RGBW LEDs for use in illumination, indication and inspection applications. Learn how the configurable WS27 Pro provided forklift guidance for warehouse operators.

  208. Local indication solutions provide clear, highly visible status alerts to both operators and plant managers in their normal sightlines.

  209. Combine bright, colorful LED indicators with wireless technology to remotely monitor your operations for real-time insights in any location and faster troubleshooting.

  210. LED indicators with advanced programming capabilities can display dynamic statuses like fill level, takt time, machine transitional states, and more.

  211. An EZ-STATUS device includes both white and color LEDs. The device can perform both task lighting and status indication functions with a single unit.

  212. In automotive manufacturing, maximizing efficiency is crucial in order to meet production goals. Delays at assembly stations can hold up processes later down the line, leading to costly wasted time and missed production targets. The TL50 Pro tower light helps assemblers meet expected cycle times and support overall takt time requirements.

  213. TL50 Pro tower lights clearly informs operators that maintenance procedures are in progress with advanced action mode animation.

  214. Indicator lights intuitively direct traffic through truck wash stations to ensure efficient flow of vehicles through the wash. However, high-pressure washdowns, cleaning agents, and outdoor environments make status indication challenging. Learn why the WLS27 segmented strip lights are a better alternative to traditional stoplights and can help improve efficiency at truck wash stations.

  215. The S15L Series In-Line Sensor Status Indicator is a two color indicator light that indicates power and output status. Its inline connection, over-molded design and bright indication create a cost-effective solution that can be applied to most 4- or 5-pin devices with an output.

  216. Learn how a retail store used TL50 Pro tower lights with USB to visually tell customers which automated checkouts were available for use, which were down for cleaning, and which were being used while they were waiting in long lines.

  217. Level measurement solutions assess fill levels and provide accurate, real-time data from a wide variety of containers or tanks.

  218. Extremely tight tolerance requirements demand a reliable solution that measures parts in micrometers to detect small variations in part size, thickness, orientation, placement, and more.

  219. Maintaining the correct level of tension on web materials ensures quality and reduces unplanned downtime. Measuring roll diameter is fundamental to maintaining appropriate web tension.

  220. Reliable web and edge guiding ensures a continuous flow of product through machine processes, minimizes downtime and prevents material damage and loss.

  221. The K50U wireless ultrasonic sensor was designed specifically as a non-contact level monitoring solution. Monitoring the levels of epoxy in drums during refill alerts staff of potential overflows before they become a problem.

  222. Banner’s U-GAGE QT50U ultrasonic analog long distance sensor has a narrow sensing beam that works in confined areas, such as the tank, without interference from the tank walls and senses with an extended range up to 8 m. The ultrasonic sensor can be mounted to the center so that the beam spreads over the tank to detect the fluid level without interference, while signaling when to pump out excess liquid and pump in additional liquid.

  223. Banner combined the technology of WORLD-BEAM QS30 opposed mode sensors, which provide high excess gain, with a 1450 nm infrared sensing beam—specially tuned to an absorption band of water, to create the QS30H2O Water Sensor. In this application, the powerful sensing beam of the QS30H2O will burn through the opaque plastic of the container. At 1450 nm, water absorbs 1,000 times the energy of alternative wavelengths, preventing the beam from burning through the liquid within the container.

  224. Elevators, escalators and moving sidewalks are major investments in any facility’s infrastructure. This equipment is expected to operate safely and reliably for many years and with minimal downtime for maintenance. To meet these expectations, a large-scale manufacturer of vertical and conveyor transport equipment performs rigorous tests on all system components. The data that is collected helps the company estimate component life expectancy and plan service schedules.

  225. The Q4X analog sensor is set up in trigger mode and uses the averaging feature to provide a more consistent fill level measurement. Banner’s Q3X sensor, whose output wire is tied to the Q4X’s remote input wire, is used to detect the leading edge of the pill bottle and has a one-shot output timer setup based on the conveyor speed to determine when and how long the Q4X will measure.

  226. 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.

  227. 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.

  228. Banner’s U-Gage QT50U ultrasonic sensor excels at the most challenging level applications, bouncing sound off any solid surface—even those that may vary in consistency or contrast. The sensor is available with a Teflon-coated transducer cover, making it resistant to harsh chemicals and suitable for the food and beverage industry. Ultrasonic sensors are able to provide accurate monitoring of pump-controlled tanks by sending a continuous signal to measure the current tank depth.

  229. Banner’s SureCross wireless system can easily transmit temperature, pressure and fill levels to a local PLCs. The wireless system will seamlessly alert operators if bottling is occurring below the desired fill level. This helps prevent errors and leads to greater consistency in bottled beverages. Consistent fill levels mean no recalls—and no wasted products. Using a wireless system also eliminates the need for slip rings on the rotary filler, which in turn reduces maintenance costs.

  230. Using a wireless level monitoring system, day tank fill levels are now monitored continuously so that materials are maintained at a specific quantity. Because these tanks are slowly filled or depleted, ultrasonic sensors can be used to measure the tank levels without false readings or tank wall interference. With a SureCross Wireless Network, FlexPower™ Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a T30UF ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. Remotely located tank sensor readings can be forwarded to a host system for data tracking, sending e-mail alerts, or to trigger specific events, such as refilling the tank. Tank resources are only filled when necessary to maintain customer-defined levels. Time is no longer wasted performing routine refills on tanks that did not need to be refilled.

  231. 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.

  232. The two-point teach option on the Q4X analog laser measurement sensor is used to teach the full and empty magazine. Manual adjustment can be used to fine tune the output. The analog output provides a real time gauge of the stack height. This allows the cartoner machine to have several “call for parts” set points without having to manually move the sensor. The Q4X is a robust, rugged stainless steel sensor ideal for use in many industrial, factory environments.

  233. Alternative data collection solutions are possible with Banner’s DX99 900 MHz radios in CID1 housings and the B/W Prostick magnetostrictive level devices. Using the appropriate antenna barrier, the result is a Class 1 Division 1 wireless monitoring solution that provides real-time data anywhere within the facility. With the battery powered DX99 units and the loop powered Prostick, installation into the 8' flanged tanks takes only a few minutes.

  234. The two point teach option on the analog setting can be used teach the front of the flat cases as the 20 mA point and can easily be adjusted for a manual set of the 4 mA to the end of the cases. This helps gauge how many flat cases are left, so more cases can be added when the case count is getting low. The digital output can also be used for presence detection. This helps ensure there is a case available to be picked up, and also ensures only one box is picked up at a time.

  235. A brew pub uses EZ-LIGHT indicator lights as a remote display of the status of the levels in the brew tanks. The indicators are connected to ultrasonic sensors within the tanks that cannot be monitored easily.

  236. Automatically monitoring the tank levels and controlling the pumps out in the gas field eliminates human error and can more quickly prevent costly spills. When the battery of salt water tanks is filled, a signal is sent wirelessly from the tank battery to the field pump to shut down the well. When the tank battery and pump are separated by miles of terrain, Banner’s MultiHop radios are an ideal solution.

  237. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.

  238. The dough for one of the company’s many popular breakfast cereals must fall within specific height parameters to ensure that it will have the perfect flake. Dough that is too thick will emerge from baking stiff and heavy. Dough that is too thin will crumble easily. This impacts the quality, taste and texture of the final product as well as product weight and packaging. Any product that does not meet the rigorous quality standards of the company will not be shipped or sold on the consumer market.

  239. Banner’s SureCross DX99 wireless FlexPower Nodes offer Class I, II, and III, Division 1 and Zone 0 certifications for installations requiring Intrinsically Safe operation. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.

  240. To wirelessly monitor and report level, pressure, and temperatures in the rotary fillers, each rotary filler was equipped with a FlexPower Node and DX81P6 6-pack battery supply. The FlexPower Node had two 0–20 mA analog inputs and one thermistor input while the battery pack supplied power to the Node and sensors for more than a year. A level probe, pressure transmitter, and thermistor (not supplied by Banner) were connected to the FlexPower Nodes and installed in the rotary tanks.

  241. An L-GAGE LT3 laser distance-gauging sensor, mounted above the hopper, measures the distance to the material's irregular surface, enabling a PLC to calculate the bin’s fill level.

  242. Banner's tower lighting solutions, such as an EZ-LIGHT TL50 Tower Light, can be mounted on top of the pump panel to easily communicate the status of the pump. The highly visible light tower allows employees to quickly check the panel, without needing to open the panel door. Multiple lights can be on simultaneously, so several messages can be conveyed at once, and the audible alert provides indication that the pump is overheating and immediate attention is required.

  243. Sensors connected to a wireless network monitor the fluid level in storage tanks. Because only 120V ac power is available at the tanks, the SureCross wireless network converts the available line power. The weather-resistant SureCross devices are protected against the elements, preventing time-consuming maintenance.

  244. The WORLD-BEAM QS18U ultrasonic sensor monitors the level of soap in a tank in a car wash. The sensor is mounted atop the reservoir, aiming through the transparent top. The sound waves bounce off the surface of the liquid.

  245. In this application, an EZ-ARRAY measuring light screen is being used to measure the length of the log. The EZ-ARRAY determines the total number of beams that are blocked by the log and communicates the length of the log to an operator station by sending the information to the system controller in the form of a MODBUS RTU-485 output. The operator station controller then provides a number of options to the operator, who selects which cuts are made.

  246. SureCross Nodes with FlexPower and Banner U-GAGE QT50U analog sensors quickly and easily facilitate these monitoring requirements without new construction and wiring. The FlexPower Node transmits the sensor data back to the Gateway device. When using a Gateway Pro, data is logged and alerts can be sent when fluid levels reach critical levels.

  247. In most waste water installations, the locations are not wired for power or data transfers. With a SureCross Wireless Network, FlexPower Nodes are deployed at each holding unit without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with an ultrasonic analog level sensor to operate for years on a single DX81 battery power supply.

  248. The bakery’s multi-staged baking process begins with mixing, kneading and fermentation and completes with proofing, baking and cooling. At each stage, experienced bakers perform quality checks for appearance, texture, size and weight. Loaves that do not meet the company’s standards are rejected for consumer sales. The company needed to build-in system capabilities to help them better manage their resources and maintain quality standards.

  249. 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.

  250. Occasionally, work stations and conveyors do not have the space available to mount sensors close to the material they intend to detect. In these scenarios, a solution is needed that can detect small items from a long distance.

  251. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with an ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. A DX80 FlexPower Node offers a combination of discrete and analog I/O in a single package, eliminating the need for time-consuming manual data collection.

  252. In most waste water or tank farm installations, the locations are not wired for power or data transfers. SureCross wireless Nodes and pressure or ultrasonic sensors can precisely monitor critical holding tank levels, sending data to a SureCross Gateway in a remote control center. Monitoring multiple data points including fill level, pH, conductivity, temperature, or flow is simplified using a single FlexPower Node with four analog inputs.

  253. Baking is a mixture of creativity, precision and attention to detail. The Wilkinson Baking Company has added technical innovation to the mix. The Wilkinson Bread Bakery is a compact, completely self-contained and fully automated bread bakery. This unique machine combines technology with tradition to transform simple raw ingredients into bakery fresh bread at 40 loaves an hour.

  254. To create a ceramic form, a vacuum is applied to a ceramic fiber suspended in an aqueous solution. Float mechanisms are ineffective for level control because the fiber adheres to the float, rendering it inoperable. Instead, a T30 UHPA ultrasonic sensor with pump in/pump out logic is used, with the power supply and 24 volt DC relay housed in a NEMA 12 enclosure behind the production line. The sensor is impervious to the washdown at the end of each shift.

  255. The existing lake level measurement system at Moncks Corner, South Carolina was aging and needed to be upgraded to newer technology. The new components, however, needed to use wireless technology for transmitting data to avoid having to run wire from the top of the dam to the dam office, located about a quarter of a mile away.

  256. A submersible pressure sensor and float switches connected to a FlexPower™ Node provide constant monitoring of water tower levels and wirelessly transmits data to a Gateway mounted near the pumps.

  257. Large facilities may have several runoff ponds in widely distributed locations. Using a wireless monitoring system eliminates the need for someone to drive out to each pond to monitor water levels.

  258. A single FlexPower™ Node equipped with a counter input and submersible pressure sensor/transmitter can be used to reliably monitor both the leachate level and the pump. The submersible pressure transmitter monitors the leachate level while the counter counts pump strokes used to remove that leachate.

  259. A Performance Mapping (PM2) Gateway and two PM2 Nodes (900 MHz, 1 W models), using the 1R mapping option, transmit the signal from the reservoir to the pump station. One of the Nodes was installed at the reservoir with the float switch as its input. A solar panel was used to power the float switch and the Node. The Gateway, also powered by a solar panel, was installed part way down the hill to act as a repeater and ensure the signal was strong between the reservoir and the pump station. The second Node was wired into the pump station’s PLC. When the signal from the float switch indicated the reservoir’s levels were low, the pump turned on.

  260. A US producer of authentic Mexican foods, such as tortillas and tostadas, strives to provide the best-tasting and freshest products for its consumers. In order to achieve this goal, consistency on the packaging line is key. The company was looking for a way to eliminate inconsistencies in their tortillas. Because they did not have a way to continuously monitor dough thickness on the production line, the dough nips often turned out either too high or too low, resulting in irregular tortilla sizes and weights. If a package of tortillas is under weight, it must be scrapped. In order to help eliminate waste and improve product consistency, the company worked with Banner to find a monitoring solution.

  261. After careful consideration of several systems, the operators of the landfill determined that the Banner Wireless system was the only solution that could meet all imposed standards and seamlessly co-exist with other devices already in place at their site. With the help of integrator Wilson Mohr, they were able to create a system that could take data from below ground and make it accessible at the desk of the end user. One battery powered Node at the top of each well powers the radio and the ultrasonic analog level sensor. Each Node is equipped with a specialized low-power 4-20 mA analog level sensor and one 10-30V dc powered Gateway controls the system. The Data Radio and Modbus master controller module enhance portability of data and an omni-directional antenna extends the range of Gateway-Node communication up and over the hill and across the landfill site. Cutting-edge power management capabilities and an internal battery eliminate long haul cabling and create a greatly-reduced cost of installation. The wireless devices also have built-in diagnostic properties that send out alarms prior to complete shutdown, minimizing down time. They are also completely scalable and can adapt as the operators fill in and create new wells.

  262. Banner’s QS30H2O sensor is a specialized sensor developed to address challenges with sensing the presence of water and water-based liquids. The QS30H2O operates in a through beam sensing mode and the emitter uses a wavelength that is tuned to not pass through water. The high excess gain of the sensor makes it powerful enough to see through an assortment of plastic and glass containers. Two pairs of sensors can be utilized to determine that the fill level has met minimum but is not overfilled and wasting product. Apertures can be placed on the receiver end to minimize the beam pattern and increase accuracy of the application. This ensures products that do not meet fill level criteria are not processed or shipped.

  263. Banner’s LTF Series Laser Measurement Sensor features high excess gain, superior signal control and automatic adaptive laser power control. These features enable reliable detection of the chewing gum from up to 12 meters away, regardless of color or reflective surfaces inside the hopper.

  264. LTF Series Laser Measurement Sensors offer tremendous accuracy over distances and are unaffected by target color or reflectivity, making them an ideal solution for monitoring loops of tread rubber. They feature high excess gain, superior signal control and automatic adaptive laser power control. Combined, these features enable reliable detection of challenging dark and reflective targets from a distance and at an angle.

  265. LTF Series Laser Measurement Sensors support a sensing range of up to 24 meters and can detect objects at or from an angle, allowing the sensor to be installed away from the inspection area where it will not come into contact with equipment or be exposed to hazards.

  266. Tracking tray levels on a denester machine ensures that product is replenished in a timely manner and does not affect production.

  267. Using K50U ultrasonic sensors and Q45U wireless nodes paired to a DXM100 wireless controller, we can develop a wireless monitoring system for multiple tank level measurements that is easy to set up, interpret the results, and monitor locally through a cloud-based system.

  268. The L-GAGE LT7 is aimed at a roll of print paper, constantly monitoring its diameter, to gauge the rate at which the printer is taking up the paper.

  269. Banner’s LE550 is factory configured with a range of 100 to 1000 mm and can start measuring immediately. If the range needs to be adjusted, the laser sensor has an intuitive user interface with a two-line, eight-character display, making it easy to automatically or manually adjust settings. The LE550 provides repeatability and accuracy across challenging targets, from metal to black rubber, allows for reliable measurement of the shrink wrap.

  270. After a convincing demonstration, the company chose Banner’s L-GAGE® LE550 laser gauging sensors to replace the ultrasonic sensors on their winders. Like the optical sensors, the LE550 is unaffected by drafts in the facility. Unlike the optical sensors, the LE550 is color insensitive. Linear array technology enables the LE550 to measure each roll, regardless of paper color, even colors that had most challenged the optical sensors.

  271. Banner’s LE550 is factory configured with a range of 100 to 1000 mm and can start measuring immediately. If the range needs to be adjusted, the laser sensor has an intuitive user interface with a two-line, eight-character display, making it easy to automatically or manually adjust settings. The LE550 provides repeatability and accuracy across challenging targets, from metal to black rubber, allowing for reliable measurement of the dark blue material.

  272. Banner’s LE550 provides repeatability and accuracy across challenging targets, including shiny, reflective surfaces like metal. The laser sensor has an intuitive user interface, making it easy to adjust settings and set up a roll diameter application, without needing to unwind the metal roll. The analog output can be used to control wind or unwind speeds.

  273. The S18U Series Ultrasonice Sensor monitors loop control on a food packaging line to detect any breaks or tears in the clear plastic film. The S18U detects targets regardless of color or transparency.

  274. Ultrasonic Sensor: Banner’s T30UX ultrasonic sensor delivers accurate distance sensing to provide a non-contact method to measure the roll of film’s diameter. By determining the roll’s radius, the vertical form fill seal machine can calculate the amount of film that remains and can signal the operator when it is low. The material should be advancing a predetermined distance equal to the desired length of each bag or package.

  275. The D10 Expert detects the web if it droops into the sensor's beam because the tension is too loose; the D10 then sends a signal to the controller to adjust the speed accordingly.

  276. The detection of clear plastic is always a challenge. The optical beam of traditional photoelectric sensors will burn through clear material, making sensing results unreliable.

  277. Banner’s T30UX ultrasonic sensor is the perfect sensor for detecting clear material for loop control because it uses sound rather than light, which makes it more accurate and cost-effective for this specific application. Although the material is clear, it presents a solid surface for an ultrasonic sensor to bounce a sound wave. The T30UX has a more accurate transducer, a smaller dead zone and minimum distance compared to other sensors that can be used for clear material detection.

  278. In the beverage industry, labels need to be applied to the bottles quickly and without error to keep production levels high. Accurately monitoring the thickness on a spool of labels and controlling the unwinding speed is very important for the process to run smoothly. A solution is needed that can accurately supervise and report the material levels on a spool in order to prevent it from running out during the manufacturing process and delaying production.

  279. 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.

  280. 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.

  281. Banner’s LX Series is an economical solution for detecting the leading edge of flat objects, such as the frozen dinner containers. With a web of modulated light, the LX Series part-sensing light screen can detect any item—in any position—passing through the light screen.

  282. It's much easier and more cost-effective to measure and monitor these transitions while the web is running than risk expensive waste in post-manufacturing inspections. As the carpet web passes through a pair of EZ-ARRAY measuring light curtains, the two sticks configured for Nap Detection mode monitor the process in action. The EZ-ARRAY detects the selvage edge and tufting edge and sends data to the web control system, which can then make necessary adjustments to keep the carpet in line.

  283. 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.

  284. The DF-G3 fiber optic amplifier, used with plastic fibers, is a precise solution for edge guiding during lithium-ion battery assembly. Proper edge guiding reduces the amount of wasted product.

  285. A drive thru vehicle detection solution can alert employees to a customer’s presence at a window, count the number of cars passing through, monitor time spent in the drive thru, and more.

  286. Vehicle detection solutions for parking applications can reliably verify when a garage is full, activate a pay station, direct drivers to available parking spots, and more.

  287. Vehicle sensing technologies verify that vehicles are correctly positioned in the car wash bay, monitor the flow of traffic, and trigger next steps like opening and closing doors.

  288. Vehicle detection at a loading dock can be used to identify available bays, facilitate fast load and unload times, verify vehicles are in the correct position before opening doors, and more.

  289. 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.

  290. Using K50U ultrasonic sensors and Q45U wireless nodes paired to a DXM100 wireless controller, we can develop a wireless monitoring system for multiple tank level measurements that is easy to set up, interpret the results, and monitor locally through a cloud-based system.

  291. A large retail shopping center reduced vehicle congestion, customer aggravation and drive-offs using wireless sensors.

  292. Sensor solutions to add vehicle detection to Fire Department dispatch and reporting systems.

  293. Sensor solution to identify correct cars are parked at charging stations, alert officers.

  294. Sensor solution required very long sensing range in a harsh weather conditions to monitor ships in ports.

  295. Wireless sensor solution to detect cars and automatically open gate in a gated community.

  296. Wireless solution to detect presence of vehicle using a long sensing range.

  297. Detect the railcar wheels and trigger an axle pushing arm wirelessly.

  298. Detect vehicles as they travel through a car wash. Sensor solution with IP69K-rated housing and infrared light to burn through mist and steam.

  299. Sensing solution for detecting trains in tunnels with high winds, dust, dirt, and debris.

  300. Sensing solution to detect cranes and warn operators of impending danger, preventing crane collisions.

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

  302. Sensor solution for bright indication inside a car wash, communicating various stages of the wash cycle.

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

  304. Solution to wirelessly detecting the entry and exit of cars in a car wash to reset a timer.

  305. Wireless monitoring solution ssed at various points in a train yard to control direction of train cars.

  306. Solution to closely monitor materials that are loaded onto a flat-bed trailer, immune to weather and light changes.

  307. Sensor solution for blind spot object detection for large vehicles, alerting operators with time to respond.

  308. Since RTG cranes are hauling such large loads, it is vital to ensure they move safely throughout the port area to avoid collisions. A sensing solution is needed to effectively implement collision avoidance for port cranes.

  309. Automated quality control ensures consistent, reliable inspection of parts and components and helps manufacturers identify potential issues early on in the manufacturing process.

  310. Identifying the cause of errors and mistakes and correcting those conditions is fundamental to error proofing (poka yoke) and promotes a Lean manufacturing environment.

  311. Visual inspection of parts and components helps manufacturers identify issues early to minimize wasted time and costs. In these applications, the right lighting is a must.

  312. Pick-to-light systems support lean manufacturing initiatives and improve quality by reducing the risk of human error in production and assembly processes.

  313. Dark packaging with multiple colors transitions can be difficult to detect with traditional red LED sensors. Banner Engineering’s miniature VS8 photoelectric sensor with blue LED works well with low reflectivity labels to detect refrigerated food packaged in pressurized cans. The small sensors fit into tight spaces and work well for short range applications. The blue LED works with the small spot size to minimize the effects of color transitions on the labels.

  314. Banner Engineering’s miniature VS8 sensor fits atop a glue gun to accurately detect the presence of adhesive as it is being applied. The VS8 is taught the distance between glue gun and PCB and can detect the very small height distance after the adhesive gets applied and recognize if there are any gaps or bubbles. The miniature sensors fit into tight spaces common in electronics assembly.

  315. 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.

  316. Banner Engineering's Q12 miniature self-contained sensor detects pucks that hold vials as they move through an automated clinical laboratory. Poor performing sensors could inadvertently cause errors and slow down the throughput of the lab. The Q12 is a good fit for clinical laboratories because it is small and can fit into confined spaces without affecting results. The fixed field sensor can also detect pucks regardless of color.

  317. • Confirm presence and orientation of IC chips • Sensor performs multiple functions at once • Cost savings and versatility

  318. The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

  319. Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.

  320. 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.

  321. 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.

  322. Banner’s Q4X laser sensor, made of 316L grade stainless steel, is very suitable for pharmaceutical environments and other aseptic filling areas. The Q4X has a sensing range of 25 to 300 mm, precise beam spot size and can effectively detect the orientation of caps as they exit a feeder bowl. If any caps are upside down, the Q4X will detect a height difference and reject the cap.

  323. 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.

  324. Banner’s DF-G2 small object detection fiber amplifier is ideal for small object detection and counting applications. The DF-G2 amplifier has a fast response speed and can detect extremely small sizes, such as 3 mm tablets or pills. When the tablets fall into bottles, it fires an output to the DF-G2 fiber amplifier, which keeps count of tablets.

  325. 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. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.

  326. 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.

  327. Banner's DF-G1 Series amplifier provides a simple setup and calibration for small part counting applications. Once the amplifier is setup, the easy-to-read digital dual display allows for simple operation because it shows the signal level and threshold simultaneously.

  328. 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.

  329. 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. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.

  330. The solution uses an iVu Series sensor configured for a Match inspection. A reference "good" identifier is taught into the sensor. In service on the production line, the sensor detects when a component does not have the correct identifier, and sends a fail output to the line, and the part is rejected.

  331. 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.

  332. The DF-GI amplifier, with the fiber optic sensing tip positioned near where the robot applies the adhesive, verifies that adhesive is applied to the IC chips. Opposed pairs of VS2 sensors detect when the level of filled wafer trays exceeds a preset height.

  333. 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.

  334. A WORLD-BEAM QS18LD diffuse-mode laser sensor can be used to accurately inspect each package as it passes on a conveyor. The sensor emits a visible Class 1 laser sensing beam, focused on the piece of tape used to seal the package. When the top of the box is closed and sealed correctly, the tape will return the sensing beam back to the receiver.

  335. 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.

  336. 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.

  337. Banner’s R55F fiber optic sensors have the capability to detect the presence of caps regardless of their color or size – a clear advantage in an industry that has a wide variety of bottle caps and frequent line changes. In this type of application, the fiber optic sensors are used to recognize long pauses between the caps which would then signal a jam to the operators of the machine. The fibers are compact and can be easily mounted in confined and typically inaccessible spaces.

  338. 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.

  339. When a production operator needs supplies, the operator toggles the switch connected to the Wireless Q45. The corresponding K50 EZ-LIGHT light on the display board lights up, signaling to forklift drivers where they are needed.

  340. Alert operators of the fail status on a checkweigh station on a food processing line in a harsh washdown environment.

  341. The customer was looking for a single-output solution that senses packages quickly, is easy to install and maintain, and was affordable enough to buy in bulk quantities if needed.

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

  343. Learn how the Q4X detects dark colored trays at hopper and filling station in the food industry.

  344. The QS18LD laser diffuse sensor scans across the top of the package to see if any flaps are open. The laser diffuse sensor provides accurate detection to verify whether the frozen packages are sealed properly.

  345. Banner’s rugged PresencePLUS P4 Sealed OMNI vision sensor works well for date/lot codes because it uses Optical Character Verification/OCV inspection to ensure the correct day and lot code are printed legibly. With an IP68-rated housing, the sensor is ideal in food and beverage applications because it can withstand harsh wash-down environments. The P4 OMNI sensor easily locates the region of the carton magazine that needs to be inspected for date/lot codes by verifying the edge of the box. Wi

  346. The unique indication of the programmable K50 Pro touch buttons and Pro Editor software allows for versatile indication of numerous machine statuses and in-field customization. Multicolor and animation allow for quick identification of errors in work cells.

  347. 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.

  348. 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.

  349. The iVu Plus Gen 2 vision system, paired with a Q4X and LEDRB backlight, offer a solution that will provide dependable results.

  350. To verify each blister in the pack, use an iVu Series sensor configured for an Area inspection. The sensor inspects each blister pack to make sure that each blister contains an unbroken tablet.

  351. 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.

  352. A single VE Series Smart Camera, adjacent to the machine’s outfeed, inspects multiple rows of blister pack trays in a single inspection. The camera is installed approximately 36 cm over the production line and an LED backlight is installed 10 cm below the production line.

  353. The Banner Q3X laser diffuse sensor is ideal for applications that require orientation detection with small contrast differences.

  354. The Q3X is Banner’s rugged, versatile laser contrast sensor, ideal for applications that require fast detection. As parts go down the conveyor, the Q3X will be able to detect if the o-ring is present based on the taught contrast differences. If the o-ring is not present, the Q3X will see a bright signal level and send an output to the PLC. This alerts operators to fix the error or move the part off of the production line.

  355. 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.

  356. 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.

  357. One global provider of healthcare products had been using vision machines to detect particulates in their liquid pharmaceuticals. When the machines were no longer able to detect contaminants to the required percentage level, the company began using human visual inspections. Since many of the particulates are extremely minute, the company needed to install bright and highly uniform illumination in their work stations so operators could effectively verify the quality of products.

  358. A VE Series Smart Camera inspects the product logo on each box before the tube of toothpaste is inserted. As a box enters the inspection area, it is detected by a sensor on the line and an output is sent to the trigger input on the camera, which captures an image of the region of interest (ROI). A red LED ring light powered by the camera enhances the contrast between the product logo and the surrounding packaging.

  359. To verify each package has a date/lot code printed on it, an iVu Series sensor is configured for a Match inspection. An image of the date/lot code is captured. When the inspection is running, if the sensor detects a package without the date/lot code the sensor sends a fail output to the line, and the product is rejected.

  360. To verify each box is correct, an iVu Series sensor is configured for a Match inspection with 360 degree rotation enabled. An image of the correct box is captured and when the inspection is running, if the sensor detects an incorrect box, the sensor sends a fail output to the line, and the product is rejected.

  361. 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.

  362. To confirm that each unit includes a product information insert, an iVu Series sensor is mounted above the packaging line. The sensor is configured for a Match inspection, and checks that the product information leaflet is inserted into each package of medication. The leaflet can be placed in any orientation, but must beface up.The sensor can detect 360 degrees of rotation to find the insert.

  363. To ensure that a stopper is properly inserted as each vial leaves the filling station, an iVu Series sensor—set up for an Area with Motion application—verifies that the vial has a stopper inserted into its neck and that the stopper is positioned correctly to provide a proper seal on the glass vial. If the stopper is missing or incorrectly positioned, then the sensor sends a fail output to the line.

  364. A sealed PresencePLUS Pro COLOR vision sensor is encased in an enclosure that protects it from damage in a wet environment. The Pro checks for label presence and placement.

  365. 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.

  366. To verify each product, an iVu Series sensor is configured for a Match inspection. An image of a good product package is captured. When the inspection is running, if the sensor detects a package with a different or missing label, the sensor sends a fail output to the line, and the product is rejected.