Limited only by your imagination, Wireless products can be used in limitless applications to communicate long or short distances without having to run cable.

Vibration Monitoring for Predictive Maintenance

Machine vibration is often caused by imbalanced, misaligned, loose or worn parts. As vibration increases, so can damage to the machine. By monitoring motors, pumps, compressors, fans, blowers, and gearboxes for increases in vibration, problems can be detected before they become too severe and cause additional damage or result in unplanned down time.

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Wireless Machine Monitoring

Manually monitoring the status of production machines is a time-consuming process. Depending on the size of the facility, manually monitoring machine status slows down production and requires additional man-hours that could be more effectively used for other tasks.

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Automated Guided Cart Control

Adding new parts to an assembly line sometimes causes problems with space requirements. When a lack of space prevents new assemblies from being readily available, production engineers can now move the parts off the line. An automatically guided cart (AGC) delivers new assemblies between the off-line area and the main production line.

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Motor Temperature Monitoring

The heat generated by failing motors and bearings can be detected before the devices shut down, minimizing facility downtime and machine damage.

FlexPower Nodes equipped with thermocouple or RTD sensors can be mounted near the monitored motors or can be mounted on AGVs for a mobile temperature monitoring system.

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Gravity Irrigation with Pump and Flow Control

Gravity fed water distribution systems for potable water and irrigation rely on pumping water uphill, often through topography that can be extremely challenging for RF communication. In this application submersible pressure sensors are used to monitor tank levels. Based on the tank water level, pumps bringing water in from a lake are turned on or off.

Counter Nodes with flow meters are used to monitor the water flowing to orchards to allow for precise water metering and accurate billing for water use. For installations without access to wired power, a solar panel or battery pack may be used to power the FlexPower Nodes and sensors.

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Tank Level, Pressure, and Temperature Monitoring

A bottling plant monitors the level, pressure, and temperature inside each rotary filler to accurately determine when to activate the inflow into the rotary filler.

To eliminate data and power wires on moving assemblies, wireless data acquisition solutions offer an alternative to masses of cables, wires, and slip rings.

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Frost Protection and Soil Moisture Control in Cranberry Bogs

Maintaining the proper soil moisture and temperature is critically important for healthy cranberry plants.

The root system of a cranberry plant is relatively shallow, requiring a specific soil moisture content to grow and produce fruit.

Air temperature is monitored to protect crops from frost. When the temperature nears freezing, the irrigation system is automatically turned on to protect the plants. Water and energy are conserved because the irrigation system is only used when the temperature is near freezing.

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Valve Temperature Monitoring at a Steam Power Plant

Engineers operating a steam power plant need to monitor the temperature of all the valves to identify possible energy losses and to schedule repairs.

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Wireless Tank Farm Monitoring in Unsafe or Harsh Conditions

Tank farms need to continually monitor various parameters, including temperature, pressure, flow, pH, conductivity, or water levels.

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Monitoring Rotating Equipment in Unsafe or Harsh Conditions

The temperature of a rotating kiln needs to be monitored and controlled.

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Wireless Monitoring Retrofit in a Pre-Certified Facility

New regulations in a pharmaceutical production facility stipulate that the liquid level of all fluids must be closely monitored and logged.

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Motor Temperature Monitoring and Control with a Wireless Network

Monitoring motor temperature in a high-friction application helps to calculate performance and to schedule maintenance.

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Wireless Tank Level Analysis in Unsafe or Harsh Conditions

Holding and Storage tanks must be continuously analyzed for various parameters, including temperature, pressure, flow, pH, conductivity, or liquid levels.

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Monitoring Rotating Equipment

The temperature of a rotating kiln needs to be monitored and controlled.

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Water, Waste Water, and Wireless Tank Monitoring

Waste water treatment plants and tank farms need to continually monitor various parameters, including temperature, pressure, flow, pH, conductivity, or water levels.

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Loading Dock Occupancy Monitoring

The receiving departments at various industries can become a hectic workspace and it's important to maintain a productive receiving area. For optimum workflow and loading dock traffic management, it is essential for dock workers to immediately know of arrivals.

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Automated Car Wash Detection

An automated car wash system needs to remain in a low-power consumption standby mode until a vehicle is detected entering the car wash.

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Existing Conduit Failing? Need to Monitor Additional or Different Areas? Need to Control New Equipment?

The traditional method for dealing with these situations is to have new conduit runs trenched or bored at great expense and inconvenience or continue to operate in a time consuming manual approach. But, does implementing a new conduit run prevent line condensation or corroding wires from occurring again? Or will it allow you to expand your capabilities regarding more sensors and controls in the future? A better option might be to implement a solution that allows you to handle your current needs as well as giving you future expansion without the cost or inconvenience of disturbing your facilities operations.

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Parking Kiosk Access and Control

Parking control systems and payment kiosks need to automatically activate when a vehicle approaches the parking lot.

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Train Yard Marshalling

As train cars pass from one sensor to another at changeover locations, track controls are activated to handle switching of subsequent cars.

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Monitoring Railcars Wirelessly

In grain stations and ports, railcar axle movers push railway cars so that train engines are not needed.

A railcar wheel monitoring system detects the railcar wheels and triggers an axle pushing arm to activate, pushing the railcar to the next loading or unloading station.

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Predictive Maintenance for Motors

If failing motors can be detected before they shut down, down time and machine damage can be minimized.

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Automatic Storage & Retrieval System

For efficient performance, automated storage and retrieval systems use a system of sensors to detect when the retrieval system is in the correct position to access products.

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Automated Parts Call

Automated guide vehicles (AGV) can be very useful in an assembly or manufacturing setting. Using an automated vehicle to delivery assembly parts to a workstation keeps the workflow and production levels high. A wireless solution helps operators keep AGVs running smoothly.

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Air Flow/Ventilation Monitoring

Regulating temperature in a livestock facility ensures optimal conditions while minimizing the loss of life. The malfunction of certain devices have the potential to directly influence the temperature within the facility. Those changes could then affect the wellbeing of the livestock. Monitoring the air in a livestock facility ensures minimum loss of life during an equipment failure.

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Wireless Water Treatment Monitoring in Unsafe or Harsh Conditions

Waste water treatment plants need to continually monitor various parameters, including temperature, pressure, flow, pH, conductivity, or water levels.

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Landfill Methane Reclamation and Flare Stack Monitoring

To meet governmental regulations, landfill managers need to accurately monitor methane gas production, removal, venting, and burning.

The ability to efficiently measure and collect data is an issue not only of resource management but also of compliance and accountability to local, state, and federal organizations.

Knowledge of both methane flow and temperature at the flare stack can define when CH4 is being emitted to the atmosphere.

Because releasing methane could be a breach of the operator’s license, an operator could be fined or forced in the future to purchase “carbon credits.”

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Vehicle Detection, Gated Community Exit

For security reasons, the entrance to a gated community is controlled by either a security guard or an unmanned system. Typically unmanned systems require an authorized code or a handheld remote to open the gate.

When exiting the gated community, however, an automatically opening gate is typically used.

Many of these communities are reluctant to install or maintain systems that damage large portions of the brick or stonework installed near the exit.

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Process Monitoring, Reporting the Location of an Activated Emergency Shower

A chemical company needs to know when and where an emergency shower is activated so that it can send a security guard to the appropriate shower to render assistance.

Though the initial installation involved only 15 showers, future plant expansion may include up to 99 individual showers spread throughout the entire facility in both indoor and outdoor locations. The farthest outdoor location is approximately one mile away from the central control location. For these reasons, a wireless notification system was an optimal solution.

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Wireless Perimeter Guarding

Storing large items outdoors presents a potential risk of property damage through vandalism or loss from theft.

Using a solar powered wireless alert system prevents damage or loss by alerting security personnel when someone has entered your outdoor storage area without clearance.

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Monitoring Rotating Kiln Temperatures

Monitoring the temperature of a kiln or oven isn’t difficult, unless it is a rotating kiln.

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, making the monitoring of rotating or moving equipment an ideal application for a wireless sensor network.

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Barn Temperature and Humidity Monitoring with a Wireless Network

Temperature monitoring in a livestock facility ensures optimum conditions or minimizes the loss of life during an equipment failure or weather changes.

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Day Tank Level Monitoring

For tank locations not wired for power or data transfer, a wireless sensor network can gather the tank data and transmit it to a central control location for analysis and logging.

Day tank fill levels are monitored continuously so that materials are maintained at a specific quantity. Because these tanks are slowly filled or depleted, ultrasonic sensors can be used to measure the tank levels without false readings or tank wall interference.

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Call for Parts in a Flooring Manufacturing Process

Four lanes of production operators needed a way to easily call the forklift drivers to deliver additional parts or to remove completed assemblies from the work stations.

To improve communication between operators and forklift drivers, unique latching output logic was developed for the K50 EZ-LIGHTs.

Combining Banner’s wireless network products and K50 indicator lights resulted in a complete parts delivery solution. This solution did not require any new cable installation and is easy to rearrange if the plant layout changes.

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Increasing Efficiency on Production Lines

Increasing production line efficiency is always a top concern for automation equipment manufacturers; reducing the amount of time technicians and managers are away from their work stations is an easy way to increase overall efficiency.

Traditional systems require operators to manually walk over to the manager area to request more work or assistance with a technical issue.

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Managing an HVAC System to Improve Efficiency

Many manufacturers run multiple production lines in the same building and oftentimes one or more lines might not be operating.

Because machinery in each line produces heat, multiple air conditioners are constantly running throughout the building. However, when only one production line is operating, having all air conditioners on is not necessary and energy is wasted.

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Replacing Cables on a Transport Cart

Transport carts move stacks of fiberboard across facilities, dragging a 36-conductor cable behind it. This cable unrolls and rolls onto a spool dozens of times a day, every day.

Over time, this cable breaks and must be replaced, causing production delays and increased maintenance costs. Operators are left trying to predict when the cable might break based on wear in attempt to avoid unplanned shutdown during production peaks.

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Monitoring Customer Traffic

Large retail stores require an easy-to-install solution for monitoring customer traffic in various parts of the store. These statistics can help optimize placement of products and advertising, thus increasing sales.

Stores must obtain these statistics without altering the shopper’s experience.

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Tank Farm Monitoring

In any tank farm, tank levels, pressure, flow rates, or temperatures must be measured accurately and quickly. When the tanks are in remote or difficult-to-access locations, there may be significant challenges with wiring and power supplies and frequent risk to personnel.

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Calculating Machine Run Time

During normal operation, operators load welding machines with frame components to be welded. The loaded parts enter a robot welding cell and a completed frame exits. Operators unload the completed frame and load more components in preparation for the next welding cycle.

If production goals are not being met, it's important to know if machine downtime or operator inefficiencies are the problem. To determine where the source, facilities need to accurately measure and report machine run time back to a control location.

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Retrofit for Robotics

Data transfer from a moving robotic arm to a control panel has traditionally been a difficult task.

Industrial wireless systems must adapt as requirements and capabilities increase. Constant maintenance and costly shutdowns caused by broken cables are currently being eliminated and replaced with more effective communication solutions.

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Monitoring Motor and Bearing Temperatures in Hazardous Areas

The dense airborne particulate in a grain elevator presents a unique challenge when collecting predictive maintenance data such as a conveyor's motor or bearing temperature.

An intrinsically safe FlexPower Node with an integrated battery powering the radio and thermocouple monitors motor or bearing temperatures without running any new wires for either power or data transmission.

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Monitoring Power Use to Avoid Peak Use Charges

Large manufacturers often rack up large energy bills; in addition to large bills, peak use penalties can also add up.

To respond to these surcharges, manufacturers can install a "smart" power system to keep the power efficiency between 95 and 100%. The plant’s power is oftentimes switched through many large banks of capacitors located away from the building. The data collection for the system is usually done manually only a few times a day. Real-time data acquisition is nearly impossible under this system.

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Monitoring Flammable Fluid Levels in a Recycling Facility

Petroleum recycling plants have unique problems in monitoring solvents in mobile tanks that are moved by semi-truck. Because these fluids are flammable, a Class I, Division 1 solution is required.

These trucks move throughout the facility to allow access to stored solvents as needed during different phases of the refining process. The facilities take in multiple kinds of solvents and oils from local industrial sites to reprocess and/or clean. After the solvents are cleaned, they are returned to the industrial site or sold for reuse.

Traditionally, personnel from the recycling plant would manually measure the tanker trucks and log the available quantities by hand on clipboards. At the end of the ay, these amounts are logged to keep track of available product and remaining storage space. The values can be inaccurate and cause ongoing problems in production, resulting in costly delays.

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Monitoring Salt Water Disposal Tanks

In most natural gas fields, salt water is removed from the ground along with the gas. This salt water must be stored in large tanks, often miles away from the gas fields.

When the salt water tanks are filled, the pumps in the field need to stop pumping the salt water to prevent salt water spills. If this salt water is spilled out of the tank, the EPA levies fines. Manually monitoring the salt water tank levels is time consuming and can result in accidental spills.

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Wireless Call for Parts Using K50 Indicators

Production operators need a safe, easy way to let forklift drivers know they need additional parts or assistance removing assemblies from work stations. Banners wireless network products combined with K50 indicator lights result in a complete parts delivery system.

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Monitoring Door Switches

The Wireless Q45 Sensors can be used with traditional magnetic reed switches to reliably monitor doors and windows to ensure safe, secure facilities.

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