Part Quality Inspection

Defects and errors in parts and components can negatively impact downstream processes, production efficiency, and product quality. Consistent, reliable inspection of parts and components can help manufacturers identify potential issues early on in the manufacturing process, minimizing lost product and production time. Banner’s expertise in a range of sensing technologies allows us to offer optimal solutions for detecting defects, measuring components, monitoring tolerances, and verifying attributes.

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  1. LED Lights Used To Inspect Liquid Pharmaceuticals

    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.

  2. Food Packaging Label Inspection

    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.

  3. Box Insert Detection

    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.

  4. Vial Placement Verification

    After a technician places vials in a tray based on each vial's color-coded lid, a PresencePLUS P4 COLOR OMNI verifies that the pattern of colored vial lids is correct.

  5. Vial Stopper Inspection

    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.

  6. Label Inspection in a Wet Environment

    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.

  7. Label Inspection

    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.

  8. Black O-Ring Detection

    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.

  9. Detecting Black Parts on Black Door Panel

    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.

  10. Wafer Center Detection with DF-G2

    By pairing Banner’s DF-G2 with four opposed mode PLIS-1 fiber optics, operators can ensure the wafer is on the robotic arm’s end effecter correctly so that no damage is done when passing it into the chamber. As the robotic arm moves the wafer into the chamber, the fiber optic beams will break and an algorithm will calculate the exact wafer position based on when the fiber sensing beams are broken. Banner’s DF-G2 has a fast response time and can quickly measure and detect the wafer’s center.

  11. Engine Block Part-In-Place Detection

    Banner’s LE550 laser sensor is ideal for part-in-place verification processes. It is reliable, and extremely accurate for small part-in-place verification from long distances. The LE550 measures for 3 mm thickness using the digital output, ensuring that the retaining clip is present and the engine block is in the correct place.

  12. Small Part Inspection in Tough Location

    Banner Engineering’s iVu vision sensor with a 50 mm C-Mount lens allows a reliable vision inspection, while extending the range to the beer bottle inspection area. This allows the sensor to be far enough away from the target, while providing the resolution needed to detect loose or missing vent tubes and spreader washers. Configured as an area sensor, the iVu TG inspects for the spreader washers’ and vent tubes’ location and presence within 16 ms.

  13. Multiple Point Inspection on Stamped Metal Parts

    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.

  14. Correct Label Verification

    An iVu TG Image Sensor works well for label verification because it comes with four sensor types, including a match sensor. The match sensor determines whether a pattern on a label matches a reference pattern and if it is correctly oriented. With just the touch of a button—or remotely through a PLC—users can easily teach the iVu image sensor to recognize and match the correct label pattern, requiring no image processing expertise.

  15. Parts Inspection on a Feeder Bowl Rail

    In this illustration, precision machined bolts have just come out of the feeder bowl and are moving down the feeder bowl rail, conveying to the next automated step. As they move down the rail, a WORLD-BEAM QS18 detects the bolt and sends a triggering signal to an inspection sensor, the iVu Image Sensor. The iVu is configured to detect a flaw in the flange, irregular shape of the bolt head, or other flaws that might be present.

  16. Pharmaceutical Insert Verification

    An iVu BCR sensor is mounted 8-12 inches above a conveyor of boxed pill bottles containing a medical information insert. The iVu BCR industrial bar code scanner reads a data matrix code on the insert to verify it matches the product on the packaging line. When a box containing an incorrect insert or no insert at all moves past the iVu BCR inspection area, the iVu detects this fail condition and sends an output alarm to the production line.

  17. Automotive Welding Tip Inspection

    The R55F high color resolution sensor checks whether the tips on a welder are within specifications, so the part being manufactured also is within specifications. In this harsh environment, the color contrast sensor uses glass fibers, for enhanced durability and heat resistance.

  18. Long-Range Inspection in Automotive Assembly

    As vehicles move forward on an automotive assembly line, an L-GAGE LT7 time-of-flight laser sensor is directed inside the sun roof to verify that the car seat has been installed and is in the correct position. It is offered in retroreflective models with two discrete outputs (PNP) for extremely long ranges up to 250 m, making it a versatile sensor in the automotive industry.

  19. Position Verification for Vial Filling

    It is critical to verify the position of the stoppers since improperly sealed or positioned stoppering can compromise the product's integrity. Vision inspection offers a flexible, powerful, and effective method to inspect for seal quality and stopper position for the vial filling process. For stoppers with full insertion, we are looking for the minimal amount of gap between the bottom of a stopper relative to the top of a vial.

  20. Part-in-Place Verification

    The WORLD-BEAM QS18 adjustable field background suppression sensor is an excellent choice for this part-in-place application, requiring a three-inch scanning distance. With the combination of high-gain characteristics, sharp adjustable cutoff and a forgiving visible red light beam this sensor ensures longevity in this harsh environment.

  21. Color Inspection and Verification

    A PresencePLUS Pro COLOR vision sensor verifies that pour spouts inserted into detergent bottles are present, fully inserted, and the same color as the bottle. The IP68 sealed housing protects the sensor and ring light from liquids.

  22. Thread Hole Detection

    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.

  23. Bottle Cap Inspection

    After bottles are filled and capped, they are conveyed under the WORLD-BEAM Q12 sensor at close range, before they are packed in cartons. The Q12 sensor, operating in fixed-field mode, detects missing or misaligned caps—regardless of color—and triggers the line to reject uncapped bottles. Because the sensor uses fixed-field mode, it responds when a cap is not at the exact distance from the sensor that it should be.

  24. Date/Lot Code Inspection

    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.

  25. Automotive Weld Nut Inspection

    After a robot inserts multiple weld nuts in an automotive component, a worker places the part onto an inspection station equipped with two PresencePLUS P4 OMNI vision sensors. Improperly inserted weld nuts could be missing, upside down, or tipped to one side. The PresencePLUS P4 OMNI inspects to see that the weld nuts are present, correctly oriented and not leaning.The vision camera compensates for part-to-part movement and can inspect from a long distance.

  26. Glue Bead Continuity Inspection

    By detecting differences in surface height, the precise laser beam of the extremely compact self-contained L-GAGE LG Series short-distance laser sensor can detect breaks in the bead of glue that a robotic glue gun applied to a panel.

  27. Bearing Inspection

    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.

  28. Drilled Holes Inspection

    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.

  29. Presence of Shrink Sleeve Label and Correct Label Verification

    The P4 OMNI vision camera is located immediately after the bottles leave the labeler which assures that the presentation of the label will be in a repeatable manner and therefore can be compared to a stored image for a match. The P4 OMNI is sealed to IP68 and made with nickel plated zinc housing.

  30. High-Speed Bottle Inspection with PresencePlus

    To rapidly verify that beer bottles are filled to the correct level and that caps are correctly aligned, a high-speed PresencePLUS P4 vision sensor locates the bottle and verifies the fill level and cap placement. This helps eliminate the need for multiple sensors, while accurately detecting the presence of caps and monitoring fill level. The red backlight provides a strong contrast to the bottles, amplifying the bottle features for easy detection.

  31. Cap Inspection in Confined Areas

    The rugged PW12-rated World-Beam Q12 sensor inspects bottle closures using fixed-field technology to ignore cap color changes. With many types of bottles and product coming down the line, it is important for the sensor to ignore the size of the cap whether it is 25 or 50 mm. Using the same fixed-field technology, the Q12 easily ignores color and size changes in caps, while detecting whether or not a cap is present.

  32. Code Inspection on Clear Bottles

    A PresencePLUS OMNI inspects the neck of a clear plastic bottle to verify that the date/lot code has been imprinted on the bottle. It also confirms that the cap is properly applied and that the bottle's fill level is within the acceptable range.

  33. Punch Hole Inspection

    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.

  34. Glass Vial Chip Inspection

    The solution uses a PresencePLUS P4 OMNI, a Standard 16 mm lens, and an On-Axis Diffused LED light. A Geometric Count tool that was used to build the inspection searches the entire image for the pattern of a good vial. The pattern consists of edge outlines of the inside and outside diameters (ID and OD) of the vial opening. A mask is used to remove the reflection from the inside bottom of the vial.

  35. Full Case Detection and Cap Color Inspection

    A PresencePLUS P4 COLOR OMNI vision sensor verifies that a case is fully packed with bottles with matching bottle caps. The sensor detects whether any bottles are missing from the case, whether any bottles are uncapped, and whether any caps are the wrong color.

  36. Food Packaging Inspection

    A high-resolution PresencePLUS P4 OMNI 1.3 mounted above a conveyor inspects each box of 12 chocolate candies, making sure each paper nest contains one candy and that the candy is intact.

  37. Detecting Plastic Wrap on a Can

    In the application shown, the plastic wrap surrounding the cap and the top of the can serves several purposes: it acts as a tamper-proof seal on the can, it prevents the cap from disconnecting during transit, and it holds the applicator tool to the can. Additionally, the plastic serves as error-proofing to protect customers from spilling the contents before they are ready to use it. For these reasons it is important that cans without the plastic wrap are rejected.

  38. Color Inspection of Pour Spouts

    A PresencePLUS P4 COLOR OMNI vision sensor inspects pour spouts that have been inserted into detergent bottles. The sensors verify that the spout is present and inserted fully, and that spout color matches the bottle color. A special bracket positions the area light at an angle that maximizes contrast and color visibility.

  39. Automotive Fuse Box Inspection

    A PresencePLUS COLOR Pro vision sensor inspects color-coded fuses in a fuse box to verify that each fuse is in the correct location.

  40. Capping and Fill Inspection

    As glass bottles pass on a high-speed conveyor, a PresencePLUS P4 COLOR OMNI confirms that each bottle is completely filled and makes sure that the stopper is fully inserted and is the correct color. The dual area lights create the optimum contrast for the inspection.

  41. Candy Color Inspection

    A PresencePLUS P4 COLOR OMNI mounted about a conveyor inspects each box of 12 chocolates, making sure each paper nest contains the correct type of candy, based on color. It rejects boxes that have the wrong chocolate in a nest, are missing product or have damaged product.

  42. Detecting Bottle Caps of Various Colors

    As plastic bottles pass below the WORLD-BEAM Q12 Sensor, the fixed-field beam identifies bottles with caps—no matter what their color—and rejects bottles that are missing caps from the line. The Q12’s laser-like LED beam sharply cutoffs at 15 mm, 30 mm and 50 mm range, ensuring it won’t mistake objects inside the bottle for caps.

  43. Orientation Verification

    This application uses an iVu Series sensor configured for a Match inspection. It ensures that the music label is face up and within a small rotational tolerance. If the sensor detects a CD that is incorrectly oriented, it sends a failure to the line, and the CD is rejected.

  44. Blister Pack Inspection by Color

    Tightened federal regulations make the quality of pharmaceutical packaging increasingly critical. A PresencePLUS Pro COLOR vision sensor inspects blister packs to make sure each blister contains the correct tablet and that the tablet is not broken. It also detects empty blisters and those containing foreign matter.

  45. Automotive Handle Color Inspection

    A PresencePLUS P4 COLOR OMNI vision sensor detects interior door handles that are the wrong color for the vehicles being assembled. An on-axis light, attached with specialized brackets, provides even, diffused illumination to reduce glare.

  46. Automotive Duct Inspection

    After a vacuum mass-airflow test of an automotive duct, a shuttle moves the PresencePLUS Pro into position above an open end of the duct. The PresencePLUS Pro verifies that a temperature sensor is still in place inside the duct and is undamaged.

  47. Plastic Injection Short Shot Detection

    A high-resolution PresencePLUS P4 OMNI 1.3 mounted above a production line inspects steering wheel components after they are molded. The P4 OMNI looks for areas with excess material or too little material.

  48. Inspecting for Missing Chocolates on a Packaging Line

    Banner sensors are positioned above a conveyor inspecting each passing box for missing chocolates. When a passing box breaks the trigger beam created by a pair of Q12 opposed-mode sensors, an array of QS18AF sensors mounted above the box inspect each location for missing chocolates. When a box containing the wrong amount of chocolates is detected, an output signal is relayed to a main controller at the packaging line warning of the failed condition.

  49. Hard Disk Detection

    Because disk surfaces are shiny, many sensors have difficulty detecting whether a hard disk is properly seated in a hard drive. The divergent-beam MINI-BEAM Expert sensor is installed above a conveyor transporting hard disks. The sensor is programmed to recognize a predetermined amount of returned light. When the sensing beam is directed onto a perpendicular specular surface, such as a properly seated hard disk, more light is returned to the receiver. The MINI-BEAM sensor pair triggers the MINI-BEAM Expert.

  50. Solder Ball Inspection

    To verify each integrated circuit, this application uses an iVu Series sensor configured for an Area with Motion application. If the sensor detects a part with missing or damaged solder balls, or if it detects any foreign material, the sensor sends a fail output to the line, and the part is rejected.

  51. Punch Hole Inspection

    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.

  52. Part Flaw Detection

    To verify an electronic component like that shown, an image of a good part was captured using an iVu Series sensor configured for a Match inspection. If the sensor detects a part with a bent or missing connector, or if the part is wrong side up, the sensor sends a fail output to the line, and the part is rejected.

  53. Labeling Detection

    In an application with limited space, the WORLD-BEAM Q20 sensor is easily positioned to verify the presence of a label before it is applied to the product.

  54. Injection Molding Inspection

    The solution involves using an iVu Series sensor configured for a Match inspection. The sensor evaluates each plastic bottle and, if the bottle is not well formed, the sensor sends a fail output to the line where the plastic bottle is rejected.

  55. Date/Lot Code Presence or Absence Detection

    Banner Engineering’s SLM series slot sensor, along with the iVu TG image sensor with Integrated Display, can be utilized to detect the passing bottles and match an image to the one printed on the bottle. During the labeling process a SLM series slot sensor is used to consistently identify each bottle as it passes by the sensor. At this point, the slot sensor will trigger the iVu vision system to verify that the codes have been printed onto the bottles.

  56. Blister Pack Inspection

    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.

  57. Blemish Detection on Bandage

    The iVu TG and iVu Plus TG are the perfect sensors to monitor materials and ensure that they meet quality standards. With an easy-to-use LCD flat-panel touch screen, the iVu gives the operator complete control and immediate feedback for setup and monitoring of products. There are three sensor types, including area, match and blemish, which is the best mode for this application.

  58. Part Orientation

    In the application shown, nuts exiting a vibratory feeder bowl are transported to the next step in the assembly process. It is essential that the correct side of the nut faces up so they can be used efficiently in the process. The iVu SeriesTG Image Sensor possesses the inspection capabilities necessary for determining part orientation. The sensor, when configured for a Match inspection, will compare each nut to a reference to determine if there is a match.

  59. Label Alignment Inspection

    As each salad dressing bottle leaves the label station, an iVu Series sensor, configured for a Match application, inspects the label and compares it to a preconfigured reference to determine if they match. The iVu verifies that each bottle has a label applied and that each individual label is applied straight and not skewed. If the label is missing, or incorrectly placed on the bottle, then the sensor outputs a signal to the labeling machine.

  60. Zero Defect Standard on Industrial Winder

    A successful manufacturer of specialty industrial yarns makes fiberglass and glass thread products for applications in the automotive, aerospace, military and composite materials industries. To help maintain their high standards and minimize costly product returns, they established a goal of zero product defects. To meet this goal, the company needed an automated thread inspection system.

  61. Detection of Cap Orientation

    The Banner Q3X laser diffuse sensor is ideal for applications that require orientation detection with small contrast differences. It offers fixed background suppression which means that the sensor can be set to recognize a specific distance and ignore anything past the set point. The Q3X is set up to detect when the top of a cap is facing toward the sensor and ignore the cap when it is facing away. When it detects a cap facing toward the sensor, a fail output is sent and the cap is rejected and removed from the line. The Q3X has a reliable sensing range up to 300mm and has a very high-speed detection rate. It can capture up to 2,000 events per second. It was also designed with an angled three-digit display to provide clear user feedback for an easy setup. It is made of rugged nickel-plated zinc making housing that is suitable for use in environments with a variety of liquids.

  62. Inspecting Blister Packs for Tablet Placement, Position and Shape

    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.

  63. Verifying Product Logo on Paperboard Packaging

    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.

  64. Detecting a Line of Adhesive on a Vehicle Door Panel

    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.