Machine Guarding

Automated production equipment, such as assembly or welding robots, material transport systems, packaging machines, press or stamping machines can pose multiple hazards to machine operators and other staff. Guarding perimeters and points of operation and access is critical to protecting personnel from accident or injury as well as preventing equipment damage. Banner has one of the most comprehensive collections of robust, easy-to-implement perimeter and machine guarding solutions in the industry, all designed to provide the highest levels of safety without compromising productivity. 

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  1. Guarding Conveyor Entry on Palletizer Machines

    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.

  2. Safeguarding at Palletizer Station with Sticky Liquids Present

    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.

  3. Guarding Personnel at Meat Slicing Machine in a Harsh Environment

    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.

  4. Simplifying Safety Feature Management [Success Story]

    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.

  5. Small Assembly Station Protection

    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.

  6. Dual-operator Robotic Work Station

    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.

  7. Depalletizer Guarding with Muting

    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.

  8. Robotic Palletizer Safeguarding

    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.

  9. Scalable Safety Control for Large Assembly Processes

    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.

  10. Safeguarding a Robotic Palletizer

    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.

  11. End-to-End Safety Sensing

    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.

  12. Manual Load Weld Cell

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

  13. Lower-Risk Machine Guarding: Carousel

    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.

  14. Lower-Risk Machine Guarding: Chip Shooter

    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.

  15. Single-Point Access Guarding

    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.

  16. L-Configured Guarding

    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.

  17. Perimeter Guarding on a Tube Bending Machine

    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.

  18. Perimeter Guarding with Mirrors

    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.

  19. Personnel Protection with Fixed Blanking and Reduced Resolution

    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.

  20. Safeguarding a Single-Station Robot Weld Cell

    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.

  21. Robotic Guarding in Work Area without Limiting Access

    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.

  22. Area and Gate Guarding on Automotive Assembly Line

    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.

  23. Machine Safeguarding in an ESD-Sensitive Environment

    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.

  24. Heat Stake Machine Safeguarding

    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.

  25. Safety Light Screens Guard Operators from Sweep Bar

    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.

  26. Safeguarding of a Power Press

    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.

  27. Depalletizer Guarding with Muting Pair

    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.

  28. Safe Material Access

    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.

  29. Safeguarding the Palletizer and Stretch Wrapper

    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.

  30. Safety of a Plastic Film Heat Sealer

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

  31. Safeguarding Access Points to a Depalletizer

    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.

  32. Safeguarding Small Access Points on Compact Equipment

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