Featured Application
Rubber Washer Detection on Engine Block

With complex assemblies, it is important to verify all parts are present to avoid defective products being shipped to the end customer. To prevent defective product from being shipped, it is vital to error proof parts by ensuring all rubber washers are present before the next step in the assembly operation.

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Assembly and Manufacturing

The number of products and applications for manufacturing and assembly is nearly endless.

Rubber Washer Detection on Engine Block

With complex assemblies, it is important to verify all parts are present to avoid defective products being shipped to the end customer. To prevent defective product from being shipped, it is vital to error proof parts by ensuring all rubber washers are present before the next step in the assembly operation.

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Detecting Black Parts on Black Door Panel

Verifying that foam and other components are present on automotive door panels is extremely important to interior trim suppliers because if any part is missing, the quality of the final door assembly is adversely affected. Delivering a bad part to the car manufacturer may result in punitive actions against the Tier 1 supplier. Since door panels are often dark colors such as black or gray, and the foam used to eliminate rattles and provide stiffness is generally black, it can be difficult for standard sensors to differentiate between foam presence and absence due to poor contrast.

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Wirelessly Monitoring Machine Status

Real-time monitoring of machine status allows operators to address any issues as they arise, minimizing machine downtime and potentially resolving small issues before they become big problems. Providing clear indication of status at a machine is a necessary requirement. Communicating status information from a machine to other devices would allow personnel to monitor multiple machines on a factory floor from a convenient location.

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Wireless Call for Parts

Operators need the correct supplies in order to build products and maintain a smooth workflow. Restocking assembly stations on-time, before components run out without overstocking and creating congestion at a station is a challenge. Real-time communication between assemblers and the forklift operators who stock their stations would enable more efficient delivery of components as well as the timely removal of completed 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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Area Guarding for Robotic Cells

When inspecting robotic results, it is important operators have access to the materials being inspected without compromising safety. In this work cell, the robot picks up and places material in a package as it moves along the conveyor. The operator uses the inspection station to ensure the package was correctly filled. It is critical this individual does not enter the protective field (red area). A solution is needed that can detect intrusion, provide a stop signal, and continually sense the inspection station is imperative.

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Call For Parts

In flexible manufacturing environments, where operators assemble components with parts supplied by parts bins, a simple indicator is illuminated to alert stocking personnel to refill the bins before parts are depleted. Keeping bins stocked with parts without the need of the operator to leave the station to retrieve and refill improves productivity.

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Counting Dropping Parts with an LX Sensor

In the assembly industry there are many small parts that need to be sorted and counted. It can be difficult to detect items as small as 5.6 mm in diameter. A solution is needed that can accurately count various small parts.

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Emergency Stopping (end-mounted rope pull)

In emergency situations it is necessary to instantly stop the motion of a conveyor to prevent any further damage to individuals or property. A rope pull that can be activated from anywhere along the length of the conveyor is ideal.

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High-Quality LED Lighting for Automation Illumination

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

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Long Bin Pick-to-Light

Lights can be useful in operation settings in order to prevent errors from occurring. It can be difficult to provide pick-to-light sensing for bins that extend beyond the front of the shelf.

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Kitting Operation with Gloves

Kitting with operator assist allows assembly line operators to focus on building high quality products, while maintaining efficiency. When operators are picking parts for multiple kits, multicolored indication can help ensure the correct parts are picked at a fast pace.

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Multiple Point Inspection on Stamped Metal Parts

Many stamped metal parts have punch holes to accommodate other parts in the assembly process. Occasionally, the hole-punch does not go all the way through, leading to inconsistencies in the stamped parts. It is vital the stamped parts are identical and holes are punched in the correct place.

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Part Pick Indication for Small Bins

Often times lights can be very useful in assembly settings to keep workflow efficient and reduce errors. They can be used to signal to the assembler which part they need to pick next in an production process.

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Sizing, Profiling and Guiding Clear Objects

To accurately perform sensing tasks including edge guiding, loop tension control, hole sizing, parts counting and on-the-fly product sizing and profiling.

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Bright Indication in Ambient Light

Many factories have use for indication status in several cabinet or workstation areas to alert operators or managers working on the floor. It is becoming more common to build large windows in factories to allow more ambient light in during the day.

Although the extreme brightness of natural, ambient light in the factory is useful for operators and other workers, the light also hinders the visibility of certain indicators across the floor, which is important to many of the ongoing manufacturing processes. It is essential to have extremely bright, highly-visible indicator lights for areas of high ambient light.

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Q4X Versatile, Rugged Laser Distance Sensor

The versatile, rugged laser distance sensor has superior performance, detecting distance changes as small as 1 mm with a reliable sensing range of 25 to 300 mm.

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Q3X Versatile, Rugged Laser Contrast Sensor

The versatile, rugged laser contrast sensor provides reliable, high-speed detection and fixed background suppression models allow for contrast detection in a fixed range while ignoring a background.

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SureCross DX80 Nodes with Analog & Discrete I/O (10-30V dc)

Analog and Discrete I/O Node provides sensing capability in a remote area and communicates data back to a Gateway.

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SureCross DX80 Nodes with Analog I/O (10-30V dc)

Analog I/O Node provides sensing capability in a remote area and communicates data back to a Gateway.

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SureCross DX80 Nodes with Discrete I/O (10-30V dc)

Discrete I/O Node provides sensing capability in a remote area and communicates data back to a Gateway.

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SureCross DX80 Wireless Networks

SureCross DX80 wireless networks consist of a radio frequency network system built around a Gateway system controller, one or more remotely located Nodes and integrated I/O.

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D10 Series

High-performance, low-contrast plastic fiber optic sensor with numeric or bargraph display

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D10—Discrete

High-performance, low-contrast plastic fiber optic sensor with gain adjustment knob.

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K80 Call Light EZ-LIGHT

Provides operational status indication for personnel, and is ideal in locations where access to power is limited or unavailable.

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WORLD-BEAM QS18 Series

Universal housing design with 18 mm threaded lens; an ideal replacement for hundreds of other sensor styles

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WORLD-BEAM QS30 Series

Universal housing, with 30 mm threaded lens mount

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WORLD-BEAM Q20 Series

PW12-rated compact sensor in worldwide standard rectangular housing

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WORLD-BEAM Q12 Series

PW12-rated rugged ultra-miniature sensor with multiple modes for accurate sensing in confined spaces

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WLB32 Industrial LED Light Bar

Banner’s WLB32 is an ultra-bright LED fixture that features an even light output to eliminate glare.

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Document Name File Size Download
1. Company Saves Money by Switching to LE550 Sensors to Measure Movement Range 504K Download
2. Manufacturer Improves Build Times Using Vision Sensor to Scan Component QR Codes 431K Download
3. Company Reduces Returns by Inspecting Small Connectors from One Meter Away 486K Download

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