Other Solutions

Reliable, versatile and easy to use and implement, solutions from Banner Engineering help companies solve challenging problems, be more competitive and achieve their automation goals. Supported by the most comprehensive catalog of automation products in the industry as well as a team of highly-trained, highly-skilled industry experts and solution architects, we are able to provide smart, high-performance solutions that solve a diverse range of applications.

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  1. Detecting Parts Ejected from Die

    In the manufacturer's facility, operators manually insert and remove metal parts from the die press. When complete, the parts are sent into a bin via a metal chute. In order to prevent die crash (having double parts in the press at once) the customer needed a sensor that could detect various parts on the chute and send a signal to the control system, indicating that the press is free and allowing the operator to perform another stroke. The solution needed to be installed without cutting slots in the chute sides or mounting sensors at the end of the chute, which could create catch points for traveling parts.

  2. Vent Tube Presence on Filler

    The rotary fillers dispense beer into bottles traveling at speeds of up to 900 bottles per minute. The company needed a solution capable of detecting spreader washers on the vent tubes as well as loose or missing tubes. However, the movement of the rotary filler and the wet washdown environment made close proximity deployments difficult and the range required for a remote solution could compromise inspection reliability.

  3. Shrink Sleeve Labeling at High Speeds

    A leading manufacturer of labeling equipment offers high-speed shrink sleeve label applicators designed to process 800 bottles per minute. To maximize the machine’s performance potential, the company wanted to install sensors capable of consistent detection and output for high-speed bottling.

  4. Pallet Detection for Conveyance Equipment

    A leading manufacturer of conveying equipment designs and builds high-quality, low-cost conveyance solutions. The pallet equipment they develop is expected to reliably convey, palletize and depalletize thousands of pallets and unit loads annually. This equipment must be able to sense a wide range of different pallet types and sizes to ensure the proper packing and unpacking of pallets and avoid line slow-downs, pallet crashes and collapses.

  5. Blue LED Sensor Detects Amber Bottles

    A recent industry switch from polypropene (PP) to polyethylene terephthalate (PETE) bottles prompted a leading US mail-order facility to re-evaluate their fulfillment process. With over 2,000 red LED sensors to be replaced, the facility turned to Banner for a solution.

  6. Remote Monitoring Calculates Machine Run Time

    During normal operation, operators load a welding machine with the frame components to be welded. The customer needed accurate machine run time data to determine why production goals were not being met.

  7. Streamlining Call for Parts or Service

    To improve efficiency, assemblers at work stations need a way to call for parts and service that doesn’t involve them leaving their work stations. Getting parts more quickly would improve production efficiency, and using a system of remote indicators would let the supervisors to see the status of each work station, allowing the supervisors to fix production problems quickly and to collect production metrics.

  8. Communication in a Busy Manufacturing Site

    As more components pass through the oven, keeping pace with the flow of items to be unloaded becomes increasingly difficult. Congestion in the sortation area builds. Items can easily be misdirected or even damaged. A pause in the flow of parts allows the unloading operator to correct mistakes and clear a pickup station. However, the distance between the unloading and loading areas as well as ambient interference from surrounding machinery complicates communication between operators.

  9. Counting Bolts Leaving a Feeder

    The D10A Discrete sensor counts bolts as they drop from a vibrating feeder bowl and pass the sensor.

  10. Juice Carton Detection

    As cartons of juice pass on a conveyor, the WORLD-BEAM QS30 sensor in fixed-field mode detects the presence or absence of a carton, regardless of color and pattern.

  11. Inspection Trigger in Printing

    The WORLD-BEAM QS30 adjustable sensor acts as a trigger for the vision sensor. When the QS30 detects the presence of a new page, it signals the vision sensor, which inspects the page's collation signature.

  12. Extendable Reach Conveyor

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

  13. Shuttle Tote Positioning

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

  14. Wirelessly Monitoring Machine Status

    Banner’s TL70 wireless tower light is ideal for this type of application. It combines high visibility indication with wireless communication. The extremely bright display of the TL70 provides at-a-glance status indication, enabling staff to easily identify the condition of a machine on the floor. Wireless communication connects the light to other devices without the time and expense associated with lengthy cable runs.

  15. Wireless Forklift Signaling

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

  16. Full Tote Indication and Verification

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

  17. Exit Chute Jam Indication

    Banner’s Q30FF600 background suppression sensor confirms when a product enters the exit chute to ensure it came off the sortation system and that there isn’t a jam in the product chute. The Q30FF600 has long range sensing up to 600 mm, which is the standard width of many chutes.

  18. Presence/Absence Item Detection

    PresencePLUS Pro II mini cameras are set up on induction stations of the sortation system for easy inspection of all items entering the system. The vision cameras can inspect and detect packages ranging from business card size to massive boxes, as well as detect packages of varying colors. The compact mini cameras and flexible mounting options provide a simple installation without the need for alterations.

  19. Sortation Auto Induction Station

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

  20. Stacker Crane Positioning

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

  21. Carton Dimensioning

    Banner’s EZ-ARRAY measuring light curtains detect items as small as 5 mm wide with an edge resolution of 2.5 mm, and have high excess gain for detecting opaque objects. These features allow for reliable detection and measurement of packages that pass through the light curtains. The total number of beams blocked for each pair indicates the size, which is sent to a sorter as an analog signal. A PLC then diverts each carton to the appropriate storage location.

  22. Parcel Collision Avoidance

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

  23. Machine Status Indication with Highly Visible, Bright Light

    With a big, bright design, the TL70 Modular Tower Light provides extremely bright and uniform light to indicate machine status. The highly visible tower light enables better visual management by allowing operators to quickly check machine status and constantly monitor machine processes.

  24. Window Tint Verification

    Banner’s DF-G1 light receiver sensor differentiates between windows with or without tint based on how much external light passes through the glass. The DF-G1 self-contained device has a simple push button set-up for easy adjustment along the conveyor. An intuitive user display allows for immediate sensor feedback.

  25. Carton Profiling

    Cartons moving on a conveyor pass between two LE550 laser sensors, measuring the width in order to sort cartons properly. The LE550 sensors are an economic solution for carton profiling. The analog output sends a signal to the PLC to deliver the carton to the correct storage location. Banner’s LE550 provides repeatability and accuracy while measuring the height, length and width of cartons. The laser sensors have an intuitive user interface, making it easy to adjust settings.

  26. Light Receiver Detects Broad Spectrum of Lights

    Banner’s DF-G1 fiber optic light receiver is a unique, cost-effective product that is designed to be placed directly in test equipment to ensure lights are functioning correctly. With the same intuitive dual display and programming interface as other DF-G1 models, the light receiver can be integrated and interfaced with assembly and test equipment control systems for pass/fail inspection.

  27. Fill Level Verification of Water Bottles

    Banner’s QS30H2O sensor is a specialized sensor developed to address challenges with optically sensing the presence of water and water-based liquids. The QS30H2O operates in a through beam sensing mode and the emitter has a unique LED with a 1450 wavelength. The 1450 wavelength is easily attenuated by water.

  28. Wireless Call for Parts

    With high-quality LED lights and multiple colors in one device, Banner's multi-segment audibleTL50, combined with the K50 Touch and PM8 wireless system result in efficient call for part processes. To begin, Banner’s K50 ergonomic touch buttons are installed in a supervisor station and numbered according to their corresponding PML8 Wireless Nodes, which are installed at individual workstations along with an audible tower light.

  29. Rubber Tire Gantry (RTG) Collision Avoidance

    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.

  30. Detecting Different Size Packages on a Conveyor

    Banner’s S18-2 barrel sensor is a cost-effective, reliable sensing method for this type of application. Its small size makes it easy to integrate along the manufacturing line, and its competitive price means it is well-suited for applications requiring multiple sensors. With a powerful and bright visible red emitter beam, the S18 sensors are easy to align during set up.

  31. Call for Parts

    Banner’s rugged, cost-effective and easy-to-install K30 Touch pick-to-light indicators are ideal for these applications because they are easy to actuate with the touch of a finger and can help industrial automation manufacturers reduce the error risk. They can be actuated with either bare hands or work gloves.

  32. Flap Detection on Cartons in Food and Beverage Industry

    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.

  33. Dough Height Inspection

    By using Banner’s L-GAGE Q50 (Q50) LED-based linear displacement laser sensors to detect dough height and depth prior to final proofing and baking, bakers can consistently maintain exact bread loaf dimensions.

  34. Carton Trigger For Date/Lot Code Printing

    With a narrow beam that projects a small bright spot, the QS18LLP laser, polarized, retro-reflective sensors provide precise position control when triggering various devices. In this application, the QS18LLP is able to correctly detect the glossy carton as it travels down the conveyor—without proxing—and trigger the ink jet printer to print the date/lot code on the carton. The second sensor triggers the P4 OMNI to inspect the date/lot code and verify it is legible and correct.

  35. Packaging Frozen Dinners on a Cartoner

    WLS28 Work Light Strips: Bright, long-lasting LED light strips provide optimal visibility inside the cartoner for operator access and easily fit on the machine without obscuring access Safety Hinge Switches: Stainless steel, load-bearing safety hinge switches support the cartoner’s machine door and will shut down the machine if the doors are opened, and minimize the risk of intentional defeat

  36. Date/Lot Code Verification

    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

  37. Emergency Stop Indication

    With the all-in-one enclosure, the emergency stop pushbutton combined with the K50 Touch lighted indicator communicates simple status indication in emergency conditions. Banner’s 30 mm mount E-Stop button has an illuminated base that turns from yellow to flashing red when actuated, clearly displaying an emergency stop condition. The K50 touch is a streamlined product with an ergonomic design that requires no physical pressure to operate and is easily actuated with bare hands or work gloves.

  38. Accurate Pallet Detection

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

  39. Highly Visible Indication in Extremely <br> Bright Environment

    Banner’s EZ-LIGHT TL50 Beacon Tower Light is visible in daylight, making it ideal for many indication status applications. It is durable and equipped with long-lasting, energy-efficient LEDs, helping guide operators on the factory floor. Displaying up to five lights in a single tower in up to 10 different colors, Banner Tower Lights offer extremely bright indication from all angles. Tower lights have an optional audible function with variable intensity that is easily adjusted and alerts operato

  40. Optical Touch Button (OTB) and Emergency-Stop Operator Station

    With the all-in-one unit, the emergency stop pushbutton combined with an OTB provides a simplified operator station for manufacturing lines that does not require wiring or additional enclosures. Banner’s 30 mm mount E-Stop buttons work well in this type of application. Their illuminated base turns from yellow to flashing red when actuated, making them compliant with emergency stop requirements. The proximity of the emergency stop button to the OTB means workers can quickly and easily actuate

  41. Forklift Crossing LED Indication

    Banner’s EZ-LIGHT® K80FL multicolor LED indicators provide simple status indication in important scenarios, such as forklift intersections on the factory floor. These unique, specialized indicator lights have highly visible, bright, even lights that easily communicate caution to factory workers. With a selection of up to three colors, specialized K80FL indicator lights can be used to communicate different signals and can be set to solid or flashing light operation with the internal DIP switch.

  42. General-Purpose Panel Indicators

    S18L general-purpose indicators are ideal for use in panels. Their intense light and bright indication easily communicates various machine stages, including cycle hold, cycle enable and fault, to factory floor workers. The S18L 18 mm indicator lights are available with up to three independent colors including green, red, yellow, blue, white, orange, turquoise, violet, sky blue and magenta. Customers can create customized panel solutions and clear indication systems on the factory floor. Workers can easily see the stages with highly bright LED indicator lights.

  43. Two-Hand Control Monitoring

    A two-hand control safeguarding system will prevent the operator from approaching the machine while a hazard is present. The machine cycle will begin only when the operator touches both Self-Checking Touch Buttons (STBs) within half a second of each other and will continue operation only as long as both hand controls are actuated, thereby assuring that the operator will remain at the control station while the machine is in use.

  44. Emergency Stop Buttons on a Conveyor

    Banner’s 30 mm mount E-Stop buttons work well in this type of application because they have an illuminated base that turns from yellow to flashing red when actuated. The red flashing illumination of the E-stop button visibly alerts operators which button was pressed so they can quickly and easily fix the problem to reduce down time and only reset the button that was activated.

  45. Monitoring Power Use to Avoid Peak Use Charges

    A SureCross DX80 wireless system can be installed to make the system work better. The DX80 Node accepts a signal from the PLC operating the smart power system that shows which capacitors are being used. The signals are transmitted to a DX80 Gateway installed in a visible location. The Gateway uses EZ-LIGHT Tower Lights to indicate which capacitors are being used and an alarm to notify personnel when energy use drifts outside the desired range.

  46. Increasing Efficiency on Production Lines

    By installing DX70 pairs, tower lights, and switch boxes, manufacturers can create a wireless notification network and communicate across the factory floor. Operators can flip switches to call a manager to the production line, call a technician, or even request parts or supplies. Using the tower light notification system reduces the need for clerks, technicians, or managers to be constantly checking each production line.

  47. Indicating Machine Status

    An EZ-LIGHT TL50 Tower Light is mounted on top of the machine to communicate its status. The highly visible light tower allows employees to quickly check the machine, without needing to constantly monitor its status. Multiple tower lights can be on simultaneously, so several messages can be conveyed at once. The Tower Light is highly visible from all angles, and the indicators appear gray when off to eliminate false indication from ambient light.

  48. Indicating AGV Call System Status

    This is an example of an Andon application, where tower lights on production lines are used to indicate operation status. This illustration, demonstrating a possible utilization of Andon light indication, has EZ-LIGHT TL50 Tower Lights mounted at each workstation to indicate the status of that workstation.

  49. Monitoring Door Switches

    By placing magnetic door switches at every exit and entry point in the plant, the Q45 Wireless can monitor door openings and closings. Switch status information is transmitted back to a central location, so that security personnel can monitor exits that should remain closed during normal operation. Each magnetic switch is connected to a DX80N2Q45RD Wireless Q45 Sensor - Remote Device model and uses the Q45’s dry contact inputs.

  50. Wireless Perimeter Guarding

    A Solar Power Supply positioned in each corner of the outdoor storage area powers both a Solar Node and SM30 Series 30mm Barrel Sensor emitter and receiver pair. To power the emitter and receiver pair, use the DIP switches to set the Solar Node's boost voltage output to 13V.

  51. Wireless Machine Monitoring

    Banner’s solution to automate machine monitoring combines a SureCross Wireless I/O Network and the Banner TL50 Tower Light indicator to create a Wireless EZ-LIGHT™. This Node provides a simple plug-n-play solution for machine status applications.

  52. Traffic Control at Loading Docks

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

  53. Syringe Inspection

    The DF-G1 sensor can be easily configured for detection of small targets, such as syringes, in a limited space packaging process. With Banner's powerful TEACH and SET methods, optimal gain and threshold can be used for a range of applications, including low contrast and long range applications.

  54. Stack Height Detection of Metal Parts

    Transfer presses require reliable part-out or feed sensing to keep the mechanical shuttle system going without causing tool damage or producing low-quality parts. If the placement or movement of metal sheets is not precisely controlled, it could result in downtime and large quantities of scrap.

  55. Sensing in Food Packaging and Conveying

    The sensing characteristics of this application are simple, yet unique: the sensors are positioned directly above a white, highly reflective background and must detect darker, lower contrast objects of varying texture. The EZ-BEAM T18 fixed field sensor is an ideal solution. It has a sharp detection cutoff and is not sensitive to color variations – it will signal the presence of an object within a certain range and ignore the background.

  56. Sensing in Food Checkweighing

    The EZ-BEAM Q25 retroreflective sensor is ideal for this application. It emits a high-powered beam that will reliably detect any dark object that passes over the scale. If clear objects are to be detected, a Q25 polarized retroreflective model is used. With its IP69K-rated housing, the Q25 is designed to withstand the harsh washdowns required in food applications. Setup is easy; the Q25 has no adjustments.

  57. Replacing Cables on a Transport Cart

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

  58. Reach Stacker Status

    Visual indication is an easy, effective way to communicate status to keep equipment operating efficiently and increase productivity. Intensely bright beacon lights are highly visible during daylight and indicate the condition of the spreader twist locks to the operator cabin to ensure a secure lift. The beacon lights feature intense levels of light output and are very rugged and durable, making them ideal for outdoor indication applications.

  59. Process Monitoring, Reporting the Location of an Activated Emergency Shower

    At each emergency shower location, a FlexPower Node with 4 discrete inputs and 4 discrete outputs and DX81 Battery Supply Module was installed. Because the installation was a Class I, Division 2 environment, the DX80...C housings were used and installed inside an appropriate enclosure. When the shower is activated by a mechanical whisker switch, the FlexPower Node sends a signal to a Gateway and controller to notify security that a shower was engaged at a specific location.

  60. Parts Detection in a Feeder Bowl

    In this illustration, caps have been loaded into a feeder bowl which consistently orientates the parts to be positioned for bottle application later in the process. The Banner QS30AF an ideal sensing solution for this application, positioned to monitor the supply level of the caps as they move out of the bowl.

  61. Pallet Transfer Safeguarding

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

  62. Motor Detection

    The robust housing of Banner’s powerful TM18 sensor is ideal for machine assembly and transport, preventing damage to the sensor while providing extremely accurate, reliable detection with opposed mode sensor pairs. Banner’s TM18 is rated to IP69K with a nickel-plated, die-cast zinc design, providing heavy-duty protection to the sensor in an industrial, automotive environment.

  63. Monitoring Customer Traffic

    To understand traffic flow and consumer habits in a retail environment, a SureCross FlexPower Node and a Banner MINI-BEAM sensor provide a discreet, peel-and-stick monitoring and counting solution.

  64. Managing an HVAC System to Improve Efficiency

    Instead of operating the HVAC system all the time, energy expenses can be reduced by scheduling the equipment to run only when the manufacturing equipment is in operation. A Node with discrete I/O monitors machine status and one of the Node’s inputs accepts a signal from the machine’s PLC to indicate if the machine is operating.

  65. Landfill Methane Reclamation and Flare Stack Monitoring

    To meet governmental regulations, landfill managers need to accurately monitor methane gas production, removal, venting, and burning. To accurately determine methane production levels and flow, a pressure transducer can detect both pressure and vacuum present within the methane production system.

  66. Gravity Irrigation with Pump and Flow Control

    The Gateway, or wireless network controller, monitors the water level inside the water tank. When the water level drops, a Node installed with the reservoir pumps uses its outputs to cycle the pumps on or off. A series of Nodes monitors the amount of water flowing into each orchard. A 1 Watt Data Radio connected to the Gateway transmits the data to a mobile asset or a centralized control center for data processing and billing.

  67. Drywall Thickness Measurement with a Network of Sensors

    A network of Banner L-GAGE LH Laser Displacement Sensors is strategically placed to make continuous thickness measurements of the sheet during the manufacturing process. If any of the paired thickness sensors make a measurement that is out of spec, the process can be stopped immediately to make adjustments and repairs to the manufacturing line. This can help eliminate scrapped material and improve the quality of the product.

  68. Detecting Pallets with Irregular Loads

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

  69. Detecting Glass Panels

    WORLD-BEAM QS18 Adjustable-Field Sensors with Background Suppression feature enhanced immunity to fluorescent lights, enabling them to reliably detect the edges of the glass panels despite looking up at the factory lights. The difficulty of varying background conditions is solved by using background suppression. The cutoff distance is set by the user with a simple multi-turn screw adjustment. The sensor will ignore objects beyond the set cutoff distance.

  70. Crane-to-Crane Communication

    Applications involving such large machinery can make wiring difficult and unsafe. Fortunately, wireless solutions allow for easy transmission of distance data. Various wireless devices can be setup up between cranes so multiple cranes can service the same area. Wireless products are also offered in rugged housing making them suitable for outdoor environments. Using wireless equipment to accurately monitor the cranes prevents costly repairs or replacements.

  71. Counting Syringes with a Slot Sensor

    In this application, the semi-transparent syringes have been oriented in a feeder bowl (not shown) and are moving down a rail in preparation for the next stage of assembly and packaging. A Banner SLM Slot Sensor is ideal for this application because the sensor housing is equipped with an emitter and receiver on the end of each fork, creating a perfectly aligned opposed-mode sensing beam for the syringes to pass through.

  72. Counting Integrated Circuits

    In order to detect these chips as they move down the conveyor, powerful sensors need to rapidly and accurately count them, but there are not many sensors that are tiny enough to fit into tight, confined spaces and still have reliable, speedy detection that keeps up with the integrated circuits as they pass by. With Banner’s ultra-miniature compact Q12 sensor, counting integrated circuits on the manufacturing line is simple.

  73. Carton Counting

    Banner’s WORLD-BEAM QS18LP laser sensor accurately inspects every carton that passes on the conveyor, ensuring the robot is triggered to load cartons into the package. With a visible laser sensing beam, the QS18LP provides precise position control, which is ideal to ensure accurate counting of cartons at a close range. The rugged QS18LP is also ideal for confined spaces and is easily set up along a conveyor for accurate sensing. With highly bright LEDs, operating status is visible from 360⁰.

  74. Call for Parts in a Flooring Manufacturing Process

    Each production operator in a lane was equipped with a wireless Node and K50 EZ-LIGHT. Another Node and EZ-LIGHT was installed in each forklift. When a production operator needs supplies, the operator pushes the button on the EZ-LIGHT, turning the light from green to red. At the same time, the forklift driver’s lights goes from green to red to indicate an operator needs parts.

  75. Calculating Machine Run Time

    PLC logic added to the welding machine can turn on an output when the allocated process time is exceeded. This output is wired to an input of a DX80 Node. The Node’s input is transmitted back to a DX80 Gateway connected to an HMI that logs overage time. Accumulated overage time is totaled for each shift and operator. Accurate work time is gathered at the welding machine and wirelessly transmitted back to a central control location for logging without running new data wires.

  76. Bright Indication in Ambient Light

    When a window is located directly behind a cabinet, extremely bright, long lasting LED indicator lights can provide highly visible indication throughout the day. Banner’s EZ-LIGHT K50 Beacon is perfect for many indication status applications, especially in this cabinet because the beacon is highly visible even during daylight and is extremely durable with long-lasting, energy-efficient LEDs.

  77. Color Sorting

    The D10 sorts gum packets by color—yellow, blue, or green—using dual-discrete outputs. The two outputs of the D10 Expert are programmed as follows: yellow is both outputs ON, blue is both outputs OFF, and green is one output ON and one OFF. The output wire of a Q12 sensor is connected to the inhibit wire of the D10 to ensure that the outputs are off when a packet is not present, so the sensor does not erroneously signal that a blue packet is present.

  78. Emergency Stopping (end-mounted rope pull)

    Banner offers various rope pull switches in spans of 6 to 100 meters, so they can run along the length of various conveyor belts. The rope pulls switches also feature heavy-duty housings suitable for harsh environments. In emergency situations, the operator can pull the rope from anywhere along the line to immediately stop the conveyor and hazardous action.

  79. Emergency Stopping (center-mounted rope pull)

    The pull rope runs along the length of a conveyor so the operator can grab and pull it from anywhere along its length to immediately stop the conveyor.

  80. Counting Memory Sticks

    As memory sticks used in digital devices pass on a conveyor, the WORLD-BEAM Q12 counts the sticks by detecting the slight difference in height between the stick and the conveyor belt.

  81. Calling an AGV for Parts

    DX80 SureCross Wireless products are a great way to communicate with automated guide vehicles in a wide variety of industries. Remote, self-contained push buttons attached to SureCross Wireless Nodes can be placed at assembly line workstations. When a specific part is needed, the push buttons can be activated and a signal sent to a Wireless Gateway-equipped AGV for replenishment of parts.

  82. Automatic Storage & Retrieval System

    SureCross FlexPower™ Nodes and low-power sensors combine to create a portable monitoring system that instantly integrates with existing Automatic Storage and Retrieval System (AS/RS) cranes. The combination of Banner’s reliable wireless solution and unique power management capability creates a host of simplified monitoring applications onboard the AS/RS crane. The FlexPower battery pack supplies power to the Node and up to four low-power sensors for years of operation. Preventative maintenance concerns can be addressed with a FlexPower Node equipped with multiple thermocouples for monitoring motor or critical bearing temperature. The communication output on the Gateway (system controller) can be used to create historical logs or trends to verify the equipment is operating at peak performance. Crane motion can be announced to staff with an EZ-LIGHT™ indicator at the end of each aisle. This bi-directional monitoring system is a simple way to alert employees that a crane is in motion without requiring any new construction or expensive downtime.

  83. Carton Sizing

    Cartons moving on a conveyor pass between three pairs of EZ-ARRAY measuring light curtains. The total number of beams blocked for each pair indicates the size, which is sent to a sorter as an analog signal. A PLC then diverts each carton to the appropriate storage location.

  84. Wafer Mapping in a Cassette

    PicoDot sensors are positioned to sense the edge of the same wafer at the same time. If only one sensor detects a wafer edge, that wafer is most likely inserted at an angle, or cross slotted.

  85. Wafer Mapping with Bargraph Display

    The fibers of the D10 Expert sensor move along the stack of wafers in the cassette, mapping which slots are occupied and which are empty. The bargraph displays the sensor's status.

  86. Conveyor Jam Detection

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

  87. Wafer Cassette Detection Under Water

    Silicon wafers are transported from one process to another in cassette on a conveyor that is totally submerged in de-ionized water. A D10 sensor has teflon-encapsulated opposed-mode fibers that are located on either side of the conveyor. When the cassette is present, the opposed beam is broken.

  88. Security/Access Monitoring with a Wireless Network

    A door to a secured storage room is equipped with a proximity sensor. When the door opens, the sensor transmits the data through a FlexPower Node to a Gateway, which illuminates an EZ-LIGHT indicator light in the main office.

  89. Center Pivot Irrigation

    Center arm pivot irrigation systems are used throughout the Midwest to minimize water use and ensure crop health. Because the sections of the center pivot assembly have to move at different speeds, the motors moving each section must be monitored to verify each section is moving at the proper speed and time.

  90. Bond Wire Break Detection with a Fiber Optic Pair

    A pair of fiber optics in opposed mode are located below the bond wire. When the wire breaks and falls through the beam, an adjustable one-shot output pulse is energized. This application does not require a consistent positioning of the bonding wire.

  91. Baggage Handling

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

  92. Liquid Leak Detection with a QS18

    In a process that uses hazardous chemicals, a fiber optic probe immediately senses liquid that touches the end of the probe. A WORLD-BEAM QS18 sensor responds by triggering a warning alarm.

  93. Communicating the Status of a Water-Pumping Station

    EZ-LIGHT Daylight Visible indicators produce intense levels of light, with 18 LEDs that can be activated together or in 3 groups of 6 to control light level intensity, making them ideally suited for applications requiring clear communication in an outdoor environment. An optional sun shield increases their visibility, making them effective even in environments with high levels of sunlight.

  94. Slip Ring Replacement with Wireless Solutions

    Slip rings are subject to constant movement which in turn leads to continuous maintenance in order to avoid degradation of the rotating electrical connection caused by normal wear and debris. Slip ring failure can be a very costly occurrence. It stops production and creates unwanted downtime. The DX80 wireless radios provide a non-contact solution for transmitting the sensor signals from inside the filler bowl to the control panel. The wireless node located on the rotary filler can be battery powered thus providing power to the sensors for a wire-free installation. The DX80 wireless solution eliminates the need for slip rings, helping to decrease downtime and maintenance.

  95. Integrated Circuit Lead Frame Detection with a D10

    The lead frame of an integrated circuit moves on a U-shaped channel toward the cassette that holds multiple frames. The D10 Expert Analog/Discrete sensor detects the leading and trailing edge, to signal to the cassette that the lead frame is approaching. The sensor operates in the opposed mode, because large differences in reflectivity of frame materials make diffuse sensing impossible.

  96. Integrated Circuit Orientation

    An iVu Plus sensor checks the orientation of each integrated circuit before is is transferred to a circuit board.

  97. Retrofitting for Pallet Detection

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

  98. Monitoring Rotating Equipment in Unsafe or Harsh Conditions

    Banner’s DX99 devices are certified for Class I, II, and III, Division 1 and Zone 0 environments, enabling data collection from unsafe locations requiring intrinsically safe operations. SureCross FlexPower I/O devices are available in metal housings with integrated battery or polycarbonate housings with an external battery supply. Taking measurements on rotating equipment, such as a kiln or rotary table, usually requires a complex and expensive system of cabling. Even taking precautions and using specialized equipment doesn’t eliminate cable tangles and breaks. The SureCross Wireless Network eliminates complexities associated with data acquisition from rotating and moving machinery such as a rotating kiln. Crucial temperature data is acquired using a thermocouple and transmitted from the FlexPowered SureCross Nodes to a remote Gateway in the plant’s control center. Excessive heat triggers an alarm. Data is always concentrated in the same location for processing or analysis, and physical risks to personnel are eliminated.

  99. Gate Monitoring Module

    The safety module monitors the magnetic sensor for actuation when the guard opens, for failure modes, and for closing. It also provides two safe switching outputs and monitoring of device under control.

  100. Door Monitoring with a Barrel Switch

    The fiber optic interlock switch guards the door without taking up much space or requiring wiring to the door.

  101. Door Monitoring in an Explosive Environment

    When the door to the guarded area opens, a break in the fiber optic beam stops the hazardous motion of a machine. Fiber optics are suitable for explosive environments, because their energy is limited and the controller is away from the hazardous area.

  102. Call for Parts (Put to Light)

    When the supply of parts runs low, the assembler presses the EZ-LIGHT K50 push button to the left, which is used as a call button to signal to the runner to bring more parts. The K50 light to the right is used as a part-pick indicator.

  103. Moveable Bracket

    The optional bracket for a one-piece EZ-LIGHT PVD pick-to-light sensor makes it possible to detach the sensor and snap it onto a different rack.

  104. Medicine Bottle Detection for Filling

    The WORLD-BEAM QS30 in adjustable-field mode detects the presence of plastic medication bottles of various colors and relays the information to a filling device.

  105. Board  Warp Detection with a QS30

    As boards pass on a conveyor, the high-sensitivity WORLD-BEAM laser QS30 detects boards that are higher than flat ones due to warping. The light-polarizing reflector mounted opposite the sensor eliminates the need to wire both sides of the conveyor.

  106. Line Problem Call

    A worker has detected a problem that might cause a quality problem down the line. The worker inserts a finger into the saddle of the EZ-LIGHT VTB, which triggers an audible alarm and displays the location on an andon board, so the supervisor can decide whether the problem merits shutting down the line.

  107. Counting Syringes Using Background Suppression

    As syringes pass on a conveyor, a WORLD-BEAM QS18 with background suppression detects the individual barrels, passing the information to a counting device.

  108. End-of-Mail Indication

    To detect this mark, use an iVu Series sensor configured for a Match inspection. The sensor detects the end-of-bundle mark, and signals the bundling machine to wrap the finished group.

  109. Soda Can Flow Control

    The Q60 background-suppression sensor detects when the flow of cans has stopped and signals the machine control that manages processes further down the line. The timing delay feature prevents the Q60 from sending the signal when it senses a small gap between cans.

  110. Mail Sorting for Size

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

  111. Sensing in a High-Speed Chip Shooter

    The bussable power feature of the D10 Expert allows for up to 16 sensors to be wired together and powered through one power supply, reducing the amount of wiring required and making it possible to use multiple sensors without needing multiple connection points. Space can be further conserved by mounting the sensors together on a DIN rail, utilizing fiber optics to monitor multiple inspection points in a confined space.

  112. Rotating Equipment Monitoring with a Wireless Network

    Battery-powered Nodes remotely transmit data—without hardwired power cables—to monitor and control rotating machines while eliminating costly and cumbersome slip rings.

  113. Rotating Equipment Monitoring

    In a number of automotive manufacturing processes, rotary tables are used to index parts into various automatic and manual work stations. In many cases, it is necessary to use sensors to verify that parts are present, properly placed, or correctly processed before indexing. Historically, the solution of using slip rings to allow sensor power and signals to be hardwired to the control system has often proven to be costly and unreliable. An alternative solution that allows more sensor signals to be processed while increasing the reliability is needed.

  114. Load Station Pallet Detection

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

  115. Indicating Checkout Lane Status in Grocery Stores

    CL50 Column Lights are mounted above each lane to indicate lane status. When the lane is open, the column light will turn green. When the lane is about to close, the light will turn red. When the lane is closed, the light will appear gray to eliminate false indication from ambient light. Column lights are rugged, cost effective and highly visible from all angles.

  116. Energy Management with a Wireless Network

    A Gateway inside a facility’s physical plant monitors energy use and demand. Depending on facility requirements—which change often—the wireless network can activate or shut down a rooftop HVAC system. With this monitoring system, industry managers can identify opportunities to make energy use more efficient and conserve plant resources at their facility.

  117. In-Line Accumulation on Single Filer

    The Q60 background suppression sensor detects when the staging area is clear of bottles or cans and the system is ready for the next layer of containers. The integral timing delay on the Q60 filters out any potentially unstable signal from the bottles as they move in a cluster. Indication is then only made when the area is truly clear and the staging area is ready for more containers.

  118. Rope Pull on Conveyors

    Banner’s RP-LS42F rope pull switches run along the length of a conveyor so the operator can grab and pull it from anywhere to immediately stop the conveyor. Spans of rope range from 6 m to 100 m, providing the flexibility to safeguard long or short conveyors. The RP-LS42 switches are compact and have a variety of accessories available for easy installation and rope tension. They are also made with heavy-impact thermoplastic housing for use in demanding industrial settings.

  119. Facility Function Monitoring

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

  120. Retrofit for Robotics

    The DX80 Gateway is positioned at the control panel to collect and process data. A DX80 Node, DX81 Battery Module, and I/O block are attached to the robotic arm. The Node allows for data gathering at the robot's end effector and also comes available with an M23 connector. The DX81 Battery Module provides power for both the Node and one external input device. These devices are easily integrated with existing equipment.

  121. Outdoor Log Debarking

    In the event of a problem or potential equipment damage, anyone along the length of the rope pull cable (up to 75 meters) can pull the cable or press the built-in E-stop button and stop the operation of the machine. The switch is ruggedly built, to allow for outdoor mounting even in inclement conditions. It provides visible rope tension indication and an auxiliary output for remote tension monitoring.

  122. Emergency Indication on Conveyors

    Banner’s RP-LS42 safety rope pulls line conveyors as a way to indicate emergencies and immediately shut down conveyors. If a rope pull is used during an emergency, it can be difficult to locate exactly where it was pulled. A K30 indicator light can be paired with the rope pulls in order to provide indication as to where the rope was pulled. This allows for quick and easy indication of where an emergency occurred, helping to return to normal operations as fast as possible.

  123. Indicating Traffic Levels in Vehicle Queues

    Either M-Gage Vehicle Detection Sensors or R-Gage Radar Sensors can be used to monitor a designated checkpoint of each lane and determine the duration of time that each vehicle is stopped at that point. This information is sent to a PLC, which is connected to a series of K80L Segmented EZ-LIGHTs in a traffic control station. The EZ-LIGHTs communicate the status of each lane to the traffic controller, who can then alert toll booth employees when their lane is backing up.

  124. Bottle Label Verification

    Banner’s Q3X versatile, rugged laser contrast sensor including background suppression is ideal for contrast applications where there is also a fixed background that needs to be ignored. In this application, the Q3X background suppression sensor detects the contrast difference between a bottle with and without a label for reliable label detection. With a range up to 50 mm, the Q3X has a tight laser spot able to detect a small change in contrast reliably.

  125. Die Protection in Tire Manufacturing

    The dies in tire presses suffer costly damage if the press tries to stamp the tread into an unstamped, or green, tire of the wrong size. To direct each tire to the correct press, Banner’s PresencePLUS P4 BCR 1.3 vision sensors sort green tires based on identifying information in the bar code printed on a label on the tire’s bead. In this application, the green tires moving on a conveyor pass below a fixture on which six BCR 1.3 vision sensors are mounted.

  126. Debarking Control

    As a log moves toward the debarker, an EZ‑ARRAY receiver determines the total number of beams that are blocked. It sends an analog signal to the debarking station logic controller, which determines the diameter of the log and adjusts the log grippers and debarking blades to the log’s size. Accurately determining the log's size provides process stability and prevents damage to the debarking machine.

  127. Objects on a Conveyor

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

  128. Detecting Items On an AC-Powered Conveyor

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

  129. Call for Parts or Service

    Small indicator lights, such as light towers, can be mounted on each workstation allowing assembly workers to quickly and easily communicate to workers on the floor. In this case, a Banner TL30 tower light is mounted at each station allowing the assembler to call for additional parts or personal assistance without interrupting the production process.

  130. Vision Sensor to Read QR Codes

    Prior to installation, engines and transmissions are coupled together on the assembly line. A worker using a hand held bar code reader scans the QR code on each transmission. The codes are small, have minimal quiet zones and are dense with embedded information. Additionally, the bar code readers have a limited range. Combined, these factors made scanning the QR codes difficult, adding time to the assembly process and diverting labor resources.

  131. Wireless Reduces Downtime

    A producer of stainless steel and special alloys supplies billets, blooms and ingots to the metal casting industry. During production, articulating robots are used to handle magnesium billets. Proximity switches located on the end effectors of the robots communicate status information from the grippers to a control panel. Robotic cables had been used to connect the proximity switches to the control panel. Environmental challenges and the motion of the robot compromised the integrity of the cables. Breaks were quite frequent and production had to be halted for repair and replacement, pushing up costs and driving down productivity.

  132. Increasing Production Line Efficiency

    An electronic component assembler needed to increase the efficiency of its production lines by reducing the amount of time technicians and managers were away from their work stations. The previous system required operators to manually walk over to the manager area to request more work or assistance with a technical issue.

  133. Monitoring a Pellet Conveyor

    A plastic blown-film extrusion company manufactures wrapping products. With over a ½ mile of various conveyor systems used to carry and mix the pellet medium, the multiple conveyor systems must remain free of blockages and mechanical failures must be detected quickly to reduce costs from wasted material, ruined batches, and costly down time.

  134. Monitoring Operator Efficiency in a Printing Facility

    A cardboard goods printer struggled with an inability to track machine operators’ efficiency and performance as measured against standard production rates.

  135. Automating Data Collection for On-Site Water Treatment

    Using Banner's wireless sensors, one company was able to focus on other outstanding maintenance issues and still reliably collect the water level data needed to comply with standard water treatment practices.

  136. Controlling Pivot Irrigation

    A municipality has over 30 farm fields irrigated with gray water using pivot irrigation systems. Local regulations prohibit the irrigation system from spraying over roads and ditches. The customer needs a solution that can reliably control the water flow to the end nozzle based on predetermined location coordinates.

  137. Collecting Snap Samples

    To collect snap samples quicker and avoid exposure to wastewater, use wireless technology to automatically collect snap samples and deliver the contents to the collection jug. A small pump installed at the collection site can be activated automatically, and at programmed time intervals, to extract the snap sample. A wireless signal is used to trigger the collection and to confirm a successful collection.

  138. Detecting Leaks Along a Coal Slurry Pipeline

    While the slurry is pumped from the mine site over hills into the retention pond, the flow rates are measured at the origination site and at the retention pond.

  139. Monitoring Machine Run Time at a Plastics Manufacturer

    To monitor downtime of each plastic injection mold press, while also avoiding the cost of running signal wires or network cables, wireless technology was put in place.

  140. Call for Parts at a Furniture Manufacturer

    The customer needs a solution that can increase the forklift operator's response time by putting indicators on the forklift's dashboard and can also allow the forklift operator to acknowledge the request, which eliminates redundant part deliveries by multiple operators.

  141. Controlling a Room Light Remotely

    A Q45 Emitter/Receiver detects when someone steps on the first step and sends a discrete signal to the Gateway to turn the light on. The light switch has a built-in timer that turns the light off after 20 minutes.

  142. Presence Detection on Rotating Lathe Turret

    Betty Machine chose the SureCross® DX80 FlexPower® wireless network from Banner Engineering. This versatile, highly-scalable solution is built around a Gateway capable of two-way communication with multiple end-point Nodes.

  143. Managing Energy Use at an Amusement Park

    Wireless technology was used to control air compressors that powered rides, saving maintenance workers time waiting for air pressure to build up.

  144.  Landfill Leachate Pump Cycle Counting

    Leachate removal from a landfill well is a primary function to guarantee consistent landfill gas production. Instead of manually collecting the pump count data, wireless technology can be used to save time and eliminate errors.

  145. Trigger Sensing on Printer

    In the beverage industry, date/lot codes are mandatory on all products in order to identify when and where a product was manufactured. Finding a solution that can accurately identify the bottle caps and then trigger a machine to print the date/lot codes onto the bottle is required.

  146. Enunciation of Safety Conditions with Visual Indication

    In order to maintain an efficient manufacturing line in the beverage industry, immediate notification of any safety issues is fundamental. Using visual and audible indication to identify safety concerns helps workers quickly find and fix the errors – returning the system to its normal operating state in a timely fashion.