Automotive Application Book April, 2014

Sensors
Automotive
Applications
Training & Support
Vision Sensors
Vision Lighting
Indicators &
Actuators
Work &
Task Lighting
Preliminary
Wireless Sensors &
I/O Networks
Safety Light Curtains
Safety Controller
www.bannerengineering.com
E-Stop
Cycle Start
Two Hand Control
April, 2014
Banner Engineering Corp. 9714 10th Avenue North, Minneapolis, MN 55441 Phone: 1.888.373.6767 www.bannerengineering.com
Body in White Contents

Adhesive Bead
Adhesive Bead
Adhesive Patch
Adhesive Daub
Robot EOAT Cable Dressing
Robot EOAT Part Presence
Model ID
Bar Code Reader
Part Sort & Verify
Body Panel Gap Measurement
Weld Cap Inspection
Tailgate Shape Conformity
Gasket Presence
Nut Detection
Part in Position
Model / Style ID Indicator
Tool-mountable Indicators
Ergonomic Cycle Start
Tool-mountable E-Stop & Actuators
Bracket Position Verify
Weld Nut Verify
Weld Nuts & Brackets
Nuts, Baffles & Gaskets
Nut in Tray Verify
Clinch Nut Postion
P4
P4
iVu
Laser Emitter
DX80
Fixed Field
P4, iVu
iVu
iVu
P4
R55F
S18U
Adjustable Field
Q45UR
Adjustable Field
TL50
EZ-LIGHT Sensor Emulator
OTB, VTB, K50, K30
OTB, VTB, K50 & K30
P4, iVu
P4, iVu
P4, iVu
P4, iVu
P4, iVu
P4, iVu
BA02
BA03
BA04
BA05
BA06
BA07
BA08
BA09
BA10
BA11
BA12
BA13
BA14
BA15
BA16
BA17
BA18
BA19
BA20
BA21
BA22
BA23
BA24
BA25
BA26
BA 01
Adhesive Bead
Objective: Provide 100% inspection of dispensed
materials: structural adhesive, mastic or sealant.
Export total inspection analysis via Ethernet IP for
traceability.
Segment: Body Assembly
Category: Error-Proofing / Quality
Type:
Adhesive
Solution: Banner P4 smart vision sensor
Value: 100% inspection ensures high quality.
Note: P4 smart vision sensors include various tools
for many error proofing applications.
The P4 bead tool is created specifically for 100% bead
inspection applications.
For bead inspection applications where critical
measurements are not required, the iVu image sensor
provides an simpler alternative.
Options: For harsh welding environments where weld
splatter is present, a borosilicate glass (BSG)
window is recommended.
When in Setup mode, the ROI is created along the bead

path for bead location. The inspection parameters are
configured for pass/ under/over bead width, plus skips etc.
P4 smart vision sensor

- sealed IP68 housing
During Run mode, pass/under/over analysis is color-coded.
BA 02
Adhesive Bead
Objective: Ensure the presence of dispensed
materials: structural adhesive, mastic or sealant with a
cost-effective solution.
Type:
Adhesive
Value: Consistent automated inspections ensures
higher quality.
Note: In this application, the P4 (non-sealed, IP20)
camera is mounted inside an enclosure and provides
multiple individual inspections at the beginning, end
and multiple points in-between, to confirm presence of
the bead.
Two area lights on either side of the camera provide
proper illumination.
P4 smart vision sensors include various tools
for many error proofing applications.
Options: For 100% bead inspections, a bead
tool is available for the P4 series.
The iVuPlus image sensor could be used in this same
spot check application proving simpler / faster set up
& maintenance and with a significant cost savings.
iVu Plus with

remote LCD touch screen
BA 03
Adhesive Patch
Objective: Verify the presence and position of the
adhesive patch.
Type:
Part Presence / Position
Solution: Banner Vision sensors
Value: The adhesive patch helps reduce vehicle NVH
(noise vibration harshness).
Note: P3 & P4 series smart vision sensors have
been used in these applications in the past with
excellent results. These devices can accurately
measure the placement of the patch, which may be
critical if its positioned near a weld-point.
The metal (image below) has a slight impression to
provide a visual reference to indicate where the edge
of the patch should be placed in order to avoid being
too close to the weld point but proper placement was
still an issue and during welding, the patch could
become ignited. The P3 cameras ensured the correct
placement and eliminated the fire risk.
Options: For more common presence or general
positioning / orientation, the iVu image sensor performs
equally well and is much simpler to implement &
maintain.
patch
metal impression
weld point
BA 04
Adhesive Daub
Objective: Improve the through-put and accuracy
of error proofing accomplished with manual visual
verification.
The mastic adhesive daubs are applied
automatically and then manually inspected
for correct placement.
Type:
Adhesive
Solution: Banner laser emitters
Value: Laser circles at the intended daub locations
provides efficient operator guidance. Operation is
now much faster (30 sec vs. 5 min) and more
precise.
The checking process is now more frequent with
push button ease - vs. the previous where the
operator needed to handle the sharp parts.
Modification is also much simpler - no more

templates are required.
Note: The old method was to use a reference part
as a template and the operator would manually draw
circles in order to compare.
Options: Laser emitters are available with different
projected shapes.
BA 05
Robot EOAT Cable Dressing

Objective: Reduce production downtime and costs
due to cable breakage.
The EOAT (end of arm tooling) contains sensors for
part presence and the clamps each have 2 sensors for
position sensing, which are plugged into I/O blocks.
The cabling that runs down the robot (dressing) may
be communications (Device Net) or discrete I/O, which
are stressed by the robots movement in highly
articulated applications and with time, fatigue and may
fail.
Category: Error Proofing / Process
Type:
Robot Cells
Solution: Banner DX80 Wireless I/O networks.
Value: Costs and production loss is reduced.
Note: The cable dressing is reduced to just DC power
and the I/O status is communicated wirelessly.
Retrofits benefit with Nodes with standard M12 QDs.
Communications from Node to Gateway (GW) is via
robust industrial RF and is not affected by the welding
process.
Options: GWs at the weld controller may provide
discrete I/O, E-IP or Modbus.
Wireless Node with:

12 - configurable I/O via
6 - M12 QD ports
BA 06
Robot EOAT Part Presence

Objective: Verify part presence on the robot grippers
with a device that provides a greater sensing than
inductive sensors.
Type:
Robot Cell
Solution: Banner Fixed-Field optical sensors.
Value: The 100mm sensing range (on the 18mm dia
sensor) allows less critical sensor positioning by
providing a greater distance to the target.
Target material & shape variations are more forgiving
than with inductive sensors.
Set-up is quicker, and failures due to being hit as a
result of being too close are eliminated.
Note: Fixed field sensors provide extremely robust
and reliable sensing in welding environments.
FF sensors have no adjustments, and feature

background suppression the ability to ignore objects
beyond their cut-off range.
Options: Different fixed field sensing ranges are
available up to 2 m.
BA 07
Model ID
Objective: Inspect body attributes to identify the model
for comparison to the build manifest.
Category: Traceability
Type:
Model ID
Solution: Banner vision sensors.
Value: Cost effective and robust verification of the
vehicle build by comparing hole patterns and structural
dimensions.
The P4 vision sensors are easily supported by the Plant;
outside integrators are not essential.
Note: Multiple vision sensors with ring lights in
individual enclosures inspect and measure body
characteristics.
Options: The sealed P4 version eliminates the need for
enclosures. The iVu image sensor offers powerful sort
capabilities and is configured via a simple LCD touch
screen; no PC required.

- IP68 housing
BA 08
Bar Code Reader

Objective: Implement an improved 2D Data Matrix bar
code reader for Direct Part Marking with Ethernet
output.
Type:
BCR / OCR
Solution: Banner iVu BCR
Value: Ethernet output provides simple interface with
the host controller.
Improved readability and easy set up; no PC is
required; all device configuration is performed on the
iVu LCD touch screen.
Note: iVu reads both 1D linear & 2D bar codes.
Options: Different light source colors are available.
iVu with C-mount lens allow ranges to 2 m.
iVu BCR
BA 09
Part Sort & Verify

Objective: Ensure the correct bracket has
been placed in the proper location.
The rear deck has a left and right support bracket, they
are different - correct part & placement needs to be
verified.
Type:
Part Position / Orientation
Solution: Banner iVu Image sensor

Value: Set up is extremely simple; inspections are
robust.
Note: No PC is required.
iVu easily discerns the pattern of the part for proper
identification.
C-Mount lens models allows longer range sensing.
Options: iVu can provide simple pass/fail signals to

traditional I/O blocks, or connect to Ethernet to provide
additional model ID / sort criteria.
Correct part loaded (pattern match) = PASS
iVu Plus with

C-mount lens
Wrong part loaded (no pattern match) = FAIL
BA 10
Body Panel Gap Measurement

Objective: Provide non-contact measurement
to verify the gap is within target tolerances.
Type:
Part Presence & Position
Value: The P4 smart vision sensor provides a costeffective fixed-mount solution for critical measurement
applications.
Note: Gap measurements took place at four points:
posterior and anterior on the right and left sides.
This installation used P4 IP20 in-line housing type.
Option: P4 in the robust sealed housing eliminates the
need for enclosures.

- IP68 housing

- IP20 in either right-angle or
in-line housing types
BA 11
Weld Cap Inspection

Objective: Verify the weld cap surface is within
specification after redress or change-out.
Type:
Welding
Solution: Banner fiber optic expert controller with
standard fibers pre-assembled to the fixture block
designed for weld caps.
Value: The quality of the weld cap redress for both tip
and crown is verified with expert contrast sensing.
Note: The fixture block is made from hardened SS the welding robot can clamp onto the fixture without
breakage.
A port for air purge allows blow-off if required.
The fibers used are standard and may be replaced in
the field if required.
Options: For weld cap profiling inspection, Banner

vision is used.
Push button teach
allows for expert
detection.
This surface flaw is
reliably detected.
R55F
Fiber Controller
Fiber Assembly
BA 12
Tailgate Shape Conformity

Objective: Verify the tailgate is true and conforms
to tolerances prior to assembly on the vehicle.
Type:
Part Position
Solution: Two Banner ultrasonic sensors mounted
on the fixture.
Value: Robust measurement error proofing
solution.
The sensors provide position repeatability
regardless if the metal surface is highly reflective
due to oil, or the surface color has changed due to
changes from the part supplier.
Note: The S18U series has push-button teach for
simple sensing window set-up.
Options: Sensor face with either a end or side view.
Different sensor sizes and ranges with

discrete and/or analog outputs are available.
Wave guide accessories focus the sensing window
for smaller sized targets.
S18U
BA 13
Gasket Presence
Objective: Verify the gasket is properly positioned on
the part prior to the process continuing.
Type:
Part Present / Position
Solution: Banner Adjustable Field sensors
Value: The longer range with adjustable background
suppression allows the sensor to be mounted to the
side and out of the way for both tool and operator
movement.
Note: Q60 series is available in both LED and laser
versions which provide different size effective beams
and range.
Options: Optional protective covers are available for
harsh environments.
Q60 with
AMS protective
bracket
BA 14
Nut Detection
Objective: Error proof the presence of the nut. The
fail conditions can be either the wrong sized nut or nut
absent.
Type:
Solution: Banner remote head style ultrasonic sensor.
Value: The remote head style ultrasonic provides submm resolution.
Note: The remote controller allows simple push-button
set-up for either 1, 2, 3, or 4mm or any custom size
sensing window.
The remote controller is IP67, may be mounted
directly on the tool and is I/O block compatible.
Options: Different remote head types are available;
this installation used the 18 mm diameter metal
threaded type.
Q45UR
BA 15
Part in Position
Objective: Improve system performance with noncontact sensors with a greater sensing range and
forgiving for target variables.
Type:
Robot Cell
Solution: Banner Adjustable Field sensors
Value: The part presence and position is verified
before the robot removes it from the conveyor.
Simple range set up via rotary adjustment .
Note: Parts are manually placed on the up feed
conveyor, fed into the cell and removed by the
automation.
Q60
AMS protective bracket
BA 16
Model / Style Indicator

Objective: Provide a lean solution for operator
guidance where parts are manually loaded on the upfeed conveyor which feed to the automation.
Category: Operator Assist
Type:
Flex Manufacturing
Solution: Banner TL50 series tower lights with
multiple pigtails for I/O block connectivity.
Value: Excellent visual indication and simple I/O block

connectivity.
Note: The indicator surface has no color until the
segment is energized and lit by colored LEDs.
The normal unlit surface versus the high contrast and
evenly illuminated energized colored surface provides
concise visual communications.
Older style indicators use colored plastic surfaces
which may appear partially lit if background light is
present and falsely accentuating its color; its OFF, but
may appear ON. Older styles were visually inefficient
between on & off states so tended to be larger
Diameter.
Options: Wrap-around labels on the pigtails to quickly
ID for I/O block port selection.
Laser etch on the segments to quickly ID the color
combinations.
Option to the two-pigtail
models: TL50 with 5-pin
QD plus a CSF series Ycord
BA 17
Tool-mountable Indicators
Objective: Improve the indication to the operator
and reduce wasted cycle time due to parts not being
properly loaded and the subsequent repeat actions.
EZ-LIGHT
Part loaded

Type:
Solution: Banner EZ-LIGHT series indicators
Value: K50L are highly visible, extremely robust
LED indicators that quickly plug to the existing
control architecture.
Their sealed, IP67 housings can be placed right on
the tool in the natural line-of-sight of the operator.
Beyond waste reduction, ergonomics are also
improved with this quickly implemented cost-saving
solution.
Note: The K50L sensor emulator indicators (proxy
lights) models provide pass/fail indication and are
connected to the sensor with a common parallel Y
cord; no other changes to the wiring or control logic
are required; no additional I/O are used.
PNP versions work with common I/O blocks and
with any common PNP sensor E.G.: inductive
proximity sensors.
Options: Colors & sizes
+
K50L
=
Parallel Y cord
Tool-mountable
EZ-LIGHT sensor emulator
proxy lights
BA 18
Ergonomic Cycle Start

Objective: Improve through-put and lower life-cycle
costs with solid-state ergonomic actuators.
Category: Ergonomics
Type:
Cycle Start
Solution: Banner ergo-actuators.
Value: Sealed IP67 and pluggable devices lower
costs and simplify the process. The robust toolmountable design reduces the need for enclosures.
Note: Both optical and capacitive types are proven in
the harsh body shop environments.
Legacy box solution
Options: VTB series is a general purpose yoke type

actuator with an integral indicator in the base.
OTB series is similar as VTB but without the indicator.
STB series is similar as well but is certified for
use in safety THC / anti-tie down applications.
K50 & K30 are capacitive actuators that detect a hand
inside of a glove, but are not falsely actuated by just a
glove without the hand.
Special laser etch available.
VTB yoke actuator
K50 with specified laser etch
Full-size cover
Compact cover
K50 touch actuator
BA 19
Tool-mountable E-Stop & Actuators

Objective: Improve life-cycle costs and simplify the
installation with connectorized self contained devices
and eliminate the traditional enclosure.
Category: Ergonomics
Type:
E-Stop, Cycle Start & Status Indicators
Solution: Banner tool-mountable control actuators
and E-stops, connectorized with QDs.
Value: Basic mounting brackets with connectorized

devices replace the traditional enclosure, eliminating
the required sub-assembly and wiring
Trouble-shooting of circuits is greatly simplified.
Note: Self-contained E-Stop devices with QDs are
quicker and easier to trouble-shoot versus each
individual e-stop screw-type terminal connection within
the enclosure to the older style E-stop.
Options: Integral indication options: none, 1, 2 or
3 colors when using I/O blocks, more with other
QD types or cables versions.
Variations in: actuator type, sizes plus brackets: with or
without space for labels.
SSA E-stop
K50 key switch

K30 push-button
BA 20
Bracket Position Verify

Objective: Verify the bracket is present and in position.
Type:
Value: The installation includes a remote ergo actuator
for the operator to use when the bracket color changes,
which may happen from batch to batch.
This remote teach function allows the operator to easily
modify the sensors threshold without needing to wait for
the technician to change the configuration.
Note: The P4 smart vision sensor is in the enclosure
beside the area light. Behind the enclosure is a live
video monitor for a quick viewing of the inspection.
Options: Today an iVu image sensor would best
resolve this application; easier to set-up and lower cost.
iVuPlus with
- IP67 housing
BA 21
Weld Nut Verify

Objective: Verify the presence and position of the two
package trays, each with two nuts.
Type:
Solution: Banner vision sensors and vision lighting.
Value: 100% quality inspection. Robust & flexible
non-contact installation.
Note: Two vision sensors in enclosures, each with
one external IR light source, are mounted above the
tool.
A quick comparison of pattern and position confirms
quality.
Options: The contemporary P4 sealed model is
rated IP68 eliminating the need for an enclosure; Its
lens-protecting window is available in borosilicate
glass which provides the best protection in weld
splatter installations.
The iVu image sensor could also resolve this
application, simplifying set-up by eliminating the need
for a computer.

- IP68 housing
iVuPlus with
- IP67 housing
BA 22
Weld Nuts & Brackets

Objective: Verify the presence and position of various
parts: horseshoe bracket, nut plate & L bracket.
Type:
Value: A low-cost, simple vision solution that doesnt
require an integrator.
Note: P4 vision sensors in enclosures, each with a
single external light source, are mounted above to
inspect nut plate & horseshoe bracket placement.
Other vision sensors are mounted to the side to inspect
the L brackets.
Options: The iVu image sensor is configured without
a computer; all set-up is achieved via its LCD
touch screen.
iVuPlus with remote LCD

touch screen
- IP67 housing
BA 23
Nuts, Baffles & Gaskets

Objective: Verify the presence and position of
nuts, gaskets & baffles.
Type:
Value: Robust, cost-effective solution.
Note: Seven P4 vision sensors are tied into a network

for monitoring, each are mounted in enclosures, each
with a dedicated LED area light.
Options: Either the sealed version of the same P4
vision sensor to eliminate the enclosures, or iVu image
sensor to eliminate the enclosures and simplify set-up
by eliminating the computer set-up.

touch screen
- IP67 housing
BA 24
Nut in Tray Verify

Objective: Verify the presence and position of the
package tray with nut.
Type:
Solution: Banner vision sensors and vision lighting.
Value: 100% quality inspection. Robust & flexible
non-contact installation.
Note: P4 vision sensors in enclosure with one external
area light, are mounted 2m above the tool.
Options: Today, the P4 sealed model or the iVu
image sensor would provide increased value and lower
costs.

touch screen
- IP67 housing
BA 25
Clinch Nut Position

Objective: Verify the presence and positioning of the
clinch nut to the part; ensure the nuts threads are
centered with the holes.
Type:
Value: Simple yet smart vision sensors intended for
the plant floor. All set-up easily executed by plant
engineering.
Note: This application used early P3 series devices.
Contemporary models provide improved performance,
easier set-up and lower cost.
Options: Today, the P4 sealed model or the iVu
image sensor would provide increased value and lower
costs.
BA 26
Body Parts Contents

Adhesive Bead
iVu
BP02
Adhesive Bead
iVu
BP03
Weld Nut Orientation
iVu
BP04
iVu
BP05
Part Presence & Position - Nut
iVu
BP06
Nut Thread Inspection
iVu
BP07
Double Part Detection
iVu
BP08
Part Presence - Spacers
Adjustable Field
BP09
BP 01
Adhesive Bead
Objective: Provide a lean bead spot check solution
for adhesive and sealant dispensers.
Verify correct single bead presence at multiple
locations through-out the dispense cycle.
Ensure correct single bead passes and fail if there is
no bead or dual bead.
Segment: Body Parts
Type:
Adhesive
Solution: Banner iVu Image sensor.
Value: Ensures the bead is present and in the
intended location with a simple, robust device thats
easy to set up and monitor.
iVu
sensor
on Robot
Note: The robot triggers the image sensor to take

a snap shot during the dispensing process at a
particular location. The sensor and the robot are
integrated in a manner to cause a fault in the event of a
defective bead.
Bead
Nozzle
The iVu remote display is mounted on the fence for

easy access.
Options: Applications requiring 100% bead
inspections and/or critical width & gap
measurement, consider the P4 series smart
vision sensor.
Pass
Fail
Fail
BP 02
Adhesive Bead
Objective: Provide a lean bead spot check to ensure
the dispensers for adhesive and sealant are
functioning properly.
Segment: Body Parts
Type:
Adhesive
Solution: Banner iVu Image sensor.
Value: Ensures the bead is present and in the
intended location with a simple, robust device thats
easy to set up and monitor.
Note: The robot triggers the image sensor to take
a snap shot during the dispensing process at a
particular location. The sensor and the robot are
integrated in a manner to cause a fault in the event
of a defective bead.
The iVu remote display provides easy access.
Older check systems monitored volume
displacement, or pressure, or flow which only verify
material flow from the nozzle but do not verify its
been properly placed on the part.
Options: Applications requiring 100% bead
Inspections and/or critical width & gap
measurement, consider the P4 series smart
vision sensor.
iVu Image sensor
BP 03

Objective: Upgrade the existing error proofing which
only checked for nut presence but did not verify
orientation of the nut.
Previous attempts to address this resulted in moderate
success but significantly impeded production.
Segment: Body Parts
Type:
Nut / Fastener
Solution: Banner iVu image sensor.

Value: Quality and through-put has been improved
with a simple-to-use robust image sensor.
Note: No PC is required for set-up.
The sensor compares and matches the placement of
each nut to a predetermined image of a properly
placed nut.
The device inspects the nut twice, once before the
cycle and once after. A fault occurring in the former will
prevent the press from cycling. A fault in the later will
prevent the welder from transferring to the next stage.
Successful weld nut inspection is dependant upon
application parameters; testing a variety of parts and
reviewing other variables is key for a robust solution.
iVu Image sensor
BP 04

Objective: Ensure the weld nuts are in the correct
orientation prior to being placed on the part.
Segment: Body Parts
Type:
Nut / Fastener
Value: Robust inspection solution with easy set-up.
Proper part is presented and the device is push-button
taught via the LCD touch screen.
Successful weld nut inspection is dependant upon
application parameters; testing a variety of parts and
reviewing other variables is key for a robust solution.
iVu Image sensor
BP 05
Part Presence & Position Nut

Objective: Verify the pierce nut has been properly
fastened, and the hole has no blockage.
Segment: Body Parts
Type:
Nut / Fastener
Value: 100 % inspection has been achieved, ensuring
the customer always receives quality parts.
The pattern match tool allows a simple push-button
teach set-up.
Options: Additional inspection for thread presence
may be achieved with the same device.
iVu Image sensor
BP 06
Nut Thread Inspection

Objective: Verify every nut has been properly
machined and has the internal threads.
Segment: Body Parts
Type:
Nut / Fastener
Value: This cost-effective error-proofing has
eliminated significant costs in returned product. when a
single bad nut has been delivered to the customer.
Note: When the threads are present, the light is
reflected back to the sensor; when absent, there is no
reflection.
This application was originally resolved with P4
vision; today iVu would be applied.
With iVu, the pattern match tool would allow a simple
push-button teach set-up on the LCD touch screen.
Options: Thread detection may also be achieved with

single point expert photoelectric sensors.
BP 07
Double Part Detection

Objective: Improve the double sheet inspection on
the press line to reduce die crashes.
Segment: Body Parts
Category: Error-Proofing / Process
Type:
Double Sheet / Part
Value: Reliably verifies single part only and detects
the presence of two parts.
This non-contact solution is easy to correctly set-up;
other types of part detection require contact with the
part where proper set-up is critical & complex.
Note: Visually, the sensor detects a 100% change
when 2 parts are present .
iVu can contain up to 30 different inspection files to
contend with different thickness metal parts.
Options: Models with remote LCD touch screen
and/or Ethernet communications.
Single Part
Double Part
BP 08
Part Presence Spacers

Objective: Verify the four spacers are in position.
Segment: Body Parts
Type:
Nut / Fastener
Solution: Banner optical sensors.
Value: The spacers are critical to the dual-wall
assembly and also support the weld nuts; 100%
inspection has been achieved in this harsh
environment.
Note: The tool is crowded at the inspection area and
the sensor needs to ignore items in the background.
The QS18 adjustable field sensors are extremely
robust and as the image shows are capable of
taking a beating; after a year of production in this weld
cell, the sides of the sensors are worn down due to
contact with the part, but still operate to specification.
Options: Accessory protective covers are now
available for harsh environments.
QS18
BP 09
Facility Content
Rooftop Exhaust Ventilation
DX80
F02
Continuous Process Monitoring
DX80
F03
Powerhouse Data Collection
DX80
F04
Rain Water Run-off
DX80
F05
Remote Process Monitoring
DX80
F06
Emergency Station Reporting
DX80
F07
Vehicle Detection
M-Gage
F08
Vehicle Detection
R-Gage
F09
Vehicle Detection
QS30 EX/RX
F10
F 01
Energy Conservation Fans

Objective: Network various loads such as roof
exhaust ventilation (REV), lighting, dust collectors etc.,
to reduce energy consumption with a solution that
installs easily and provides a good ROI.
Segment: Facility
Category: Energy Conservation
Cost Savings
Type:
Solution: Banner wireless I/O networks.
Value: Loads can be scheduled to turn on & off
automatically with robust wireless monitoring & control.
Installation is quick and less expensive than other
networking solutions.
The loads are controlled (scheduled or event driven)
via the host EMS system.
Note: The existing loads may have a start/stop
pushbutton or selector switch for local manual control
of the contactor that switches the load. The Banner
solution adds the networking capability to the local
control to facilitate timely shut down and start up for
breaks, lunch, end of shift and weekends.
The REV Solution includes:
A) Node Enclosure: a compact non-metallic enclosure
with Node & antenna, power supply, relays and
terminal strip.
B) Gateway Sub-panel with GatewayPro for Ethernet
communications plus a IP67 Power supply.
GatewayPro
Node with
external
terminals
F 02
Continuous Process Monitoring

Objective: Improve efficiencies and lower costs with
real time monitoring of plant processes.
Segment: Facility
Type:
Process Monitoring
Value: Energy reduction and trending analysis provide
multiple cost savings with an industrial robust radio
solution.
Note: Temperature, pressure, differentials, levels
etc., are used to identify plant energy losses and
repairable leakage-related degradation factors.
GatewayPro
Node with
internal
terminals
F 03
Powerhouse Data Collection

Objective: Implement a wireless data collection
network between the chart recorders in the
powerhouse and the central host control.
Segment: Facility
Type:
Process Monitoring
Value: The older monitoring process is in place with
existing analog sensors connected to the paper chart
recorders.
The addition of Banner Nodes is a low cost and simple
installation that provides real-time use of the data.
Collection of the paper charts is now redundant.
Note: Placing a Node at each of the Chart Recorders
and wirelessly transmitting the analog data to the
Gateway located at an access point allows real-time
input of the data.
Options: The chart recorders can be removed
altogether and the analog sensors input the Node
directly.
IS Certified Nodes are available.
GatewayPro
IP67 Node with

internal
terminals
F 04
Rain Water Run-off

Objective: Monitor rain water run-off levels in ponds
and waterways.
Segment: Facility
Category: Environmental
Type:
Process Monitoring
Value: Low cost solution to comply with EPA and
Clean Water Act requirements.
Note: A submersible pressure transducer is placed in
each pond and is connected to the battery powered
wireless Node on the shore.
In this example, the three retention ponds are
separated by up to a mile and several buildings.
This level monitoring application used MultiHop data
radios to transmit level information back to a central
control location.
Options: Other types of sensor (level, flow etc) could

be used; consideration is given to sensor current draw
and reporting interval.
Pond 1
Pond 2
Master
Pond 3
F 05
Remote Process Monitoring

Objective: Provide continuous monitoring and control
for the remote Tank Farm.
Segment: Facility
Type:
Tank Farm
Value: Banner nodes can accept a wide range of
sensors and transmit the data between buildings and
across plants.
Banner wireless is highly scalable; changes -or
additions- to where the information needs to be sent is
easily achieved.
Note: Banner V dc line-powered Nodes can accept
most types of sensor inputs, either analog or discrete.
Options: Banner flex-powered Nodes can accept
energy-managed sensors for unique battery powered
solutions.
F 06
Emergency Station Reporting

Objective: Monitor emergency devices such as eye
wash stations and defibrillators to provide an alarm if
used.
Segment: Facility
Category: Human Resources
Type:
Safety Showers and Eye Wash Stations
Value: If the emergency device is used the location
is communicated to plant security and the medical
team for a quicker response.
Note: Flow or actuation of the device could be via a
discrete signal while temperature monitoring could be
achieved with thermocouple or other sensor.
ANSI Z358.9 (2009) for Safety Showers and Eye Wash
Stations requires certain compliance issues.
Options: Battery Powered solutions provide a
completely wireless solution.
F 07
Vehicle Detection
Objective: Replace the induct loop sensors with
more robust, easier to install solution.
Segment: Facility
Category: Door Controls
Type:
Vehicle Position
Solution: Banner M-Gage series magnetic field
sensors .
Value: Operating costs are reduced and the system
is more reliable.
Note: M-Gage provides a direct replacement for
inductive loop systems and requires no external
frequency box. Its unique design allows quick
installation within a core hole. For best performance,
mount the sensor below-grade, in the center of the
traffic lane.
M-Gage is not affected by temperature, moisture, dirt
or other environmental parameters.
Options: M-Gage is available as a wired DC sensor

and can be surface mounted, or located inside
aluminum architectural components. The flat-pack
housing style is intended to fit within a 1/4" or 6 mm
(road surface) saw cut and buried.
The wireless M-Gage intended to be buried; range is
reduced ~ 300 m.
18mm diameter M-Gage
Flat Pack M-Gage
Wireless M-Gage
Wireless
Gateway
Receiver
F 08
Vehicle Detection
Objective: Improve the door controls with a more
reliable single-sided sensor type.
Segment: Facility
Type:
Vehicle Presence
Solution: Banner R-Gage series radar sensors .
Value: Robust sensor that reliably detects cars, trucks
and trains in extreme weather conditions.
Note: Radar sensors use Frequency Modulated
Continuous Wave (FMCW) radar to reliably detect
moving or stationary targets.
Unlike Doppler radar, these continuously sweeps
across a range of frequencies to determine distance as
well as motion.
Options: Variations in models for range and detection
mode plus country-specific approval certificates.
R-Gage
F 09
Vehicle Detection
Objective: Upgrade the sensors on the door
controls with a harsh-duty optical sensor to contend
with any weather conditions.
Segment: Facility
Type:
Vehicle Presence
Solution: Banner harsh-duty photoelectric sensors.
Value: The QS30 EX/RX opposed mode sensor is
IP69K rated for extreme environmental conditions,
wide temperature fluctuations and high humidity
conditions.
It is optically tuned to penetrate mist and fog, be
sunlight immune, and reliably detect cars and trucks.
Note: 30 mm threaded barrel or right-angle mounting
options; lens designed to shed water and debris
Infrared beam with high excess gain (burn-through) for
reliable sensing in heavy fog, mist, dust and industrial
process contamination.
Bright LED operating status indicators visible from
360.
QS30 EX/RX
F 10
Logistics Content
Material Call
Material Load/Unload
DX80 Q45
Ultrasonic
L02
L03
L01
Material Call
Objective: Improve the existing Material Call
application by implementing radio with two-way
communications.
Segment:
Category:
Type:
Logistics
Line-side delivery
Pull System
Solution: Banner DX80 series wireless networks

provide two-way communications. The Q45 Call Button
includes an integral bi-color LED indicator.
Value: Two-way RF communication provides feed-back
to the line-side operator; theyll know their request has
been received and when the delivery vehicle is on its
way.
There is no initial software to purchase and no on-going
updates to be implemented.
Notes: The Q45 Call Buttons are located along the
assembly line and communicate wirelessly with the
DX80 GatewayPro.
DX80 GatewayPro with EthernetIP communicates
directly to the Host production system via an access
point.
Two-way communications allows the host to
respond to the operator:
Color 1 = request for parts message received.
Color 2 = the delivery vehicle is on its way.
Options: Automate the material call with Q45 wireless
sensors which detect & signal low levels.
Q45 Call Button
L02
Material Load / Unload

Objective: Verify the proper position of the fork
lift trucks when they load and unload parts.
Segment:
Category:
Type:
Logistics
Line-side delivery
Vehicle Position
Solution: Banner ultrasonic sensors.

Value: High repeatability of the switch-point
and robust performance.
Note: T30U series has push-button teach for
simple set-up.
Ultra-sonic sensors are not affected by surface
color variations.
T30U series
L03
General Assembly Contents

Hole Detection
2D BCR / Window
A/C Fill Line Monitor
RF Remote Actuator
Rope-pull Actuator
Andon add-on
Part Picks
Line-side Part Picks
Line-side Status Indicator
Line-side Key Switch
Over-travel Indicator
Indicator Retrofit
Bulk Part Picks
Bulk Part Picks
Kitting Part Picks
Kitting Part Picks
Part Removal
Tool Nest Sensor / Indicator
Vehicle Detection
Vehicle Detection
Glass Detection
Glass Inspection
Glass Tint Verification
Vehicle Transfer Lift
Vehicle Position
Vehicle Position
Carrier Bearing Temperature
AGV Communications
AGV Communications
Part ID/Laser
Position Mapping/Lasert
iVu
iVu
DX80
DX80-Q45 & K50L
K50 & Rope-Pull bracket
K50L
PVL
PVA
PVA
VTB
TL50
K50
TL50
TL50
K50
PVA, VTB
K50
PTL
LX
LX
QT50U
Ultrasonic
Ultrasonic
Fibers & Q60
Light Intensity Sensor
Ultrasonic
Q60
LT3
T-Gage
DX80
T-Gage
DX80
Q60
L-Gage
GA02
GA03
GA04
GA05
GA06
GA07
GA08
GA09
GA10
GA11
GA12
GA13
GA14
GA15
GA16
GA17
GA18
GA19
GA20
GA21
GA22
GA23
GA24
GA25
GA26
GA27
GA28
GA29
GA30
GA31
GA32
GA33
GA34
GA35
GA 01
Hole Detection
Objective: Identify the presence of the hole to signal
trim options.
Segment: General Assembly
Type:
Model ID
Value: The iVu is simple to set-up and maintain; no
PC is required.
Note: The lens and light selection determines the FOV
field of view and range.
For ranges up to 2 m, the iVu with c-mount lens is
used; for closer ranges to 30 cm the micro video lens
types are often used.
Options: iVu can provide either discrete signals with
I/O Block connectivity, or communicate via Ethernet
IP.
iVu with c-mount lens and

3-branch I/O block cord
GA 02
2D BCR / Window
Objective: Read the Data Matrix 2D bar code on the
rear window before the automation removes the part
from the rack.
Type:
Model ID
Solution: Banner iVu BCR sensor.
Value: The iVu BCR reads both 1D linear and 2D bar
codes; no PC is required.
Note: The lens and light selection determines the FOV
field of view and range. For ranges up to 2 m, the
iVu with c-mount lens is used; for closer ranges to 30
cm the micro video lens types can be used.
Options: iVu provide both serial and Ethernet IP
communications. iVu is available with integral or
remote LCD touch screen.
GA 03
A/C Fill Line Monitor

Objective: Provide a wireless solution to add a limit
switch to the moving a/c purge & fill equipment that
travels independently to the moving assembly line.
Type:
Fluid Flow
Solution: Banner Wireless I/O
Value: The production problem that caused damage
to both vehicle and equipment if the hose apparatus
was not removed in time is now eliminated.
Note: Multiple a/c & purge moving stations travel
along side of the assembly line and are manually
connected to the vehicle to start the process. The
vehicle continues a short distance when another
operation is to manually disconnect it and seal the a/c
system. Occasionally the operator doesnt reach it in
time and the fill/purge lines are pulled tight and cause
damage to the vehicle and the equipment.
Now a tension-type limit switch is added which is wired

to the Node. If the same condition occurs, the fluid
lines disconnect in a controlled fashion and the host
control is wirelessly communicated which shuts off the
process.
GA 04
Andon Remote Actuator

Objective: Improve the Andon RF remote actuation
device.
The current devices are not reliable: poor radio
Performance, short range in plants and the batteries
have a short life.
Type:
Andon
Solution: Banner DX80 series wireless devices with

Q45 Remote Actuator and K50L indicators.
Value: Excellent radio performance; batteries have a
long life and are quick & easy to change. The Actuator
also has integral Andon indication.
Note: In assembly where the operator cannot easily
access the rope-pull or other actuators, the Q45 RF
remote actuator can be placed within easy reach.
M12 connection
to standard I/O
blocks
DX80 radio
Gateway
The Q45 remote actuator has an LED indicator

that provides additional Andon indication.
Typical operation: when activated, the Gateway signal
is sent to the host via pin 4. The host controls the
K50L indicator via pin 2.
Other systems may use a GatewayPro with E-IP
communications to a host or smart Andon marquee.
All Banner radios provide two-way communications
with an integral heart-beat / health function. In the
case of battery failure, the radio can have the K50
indicator change to an alternate color to indicate the
need for a battery change.
Options: Other Andon actuator type include: rope-pull
and ergo grip.
K50L LED indicator

OFF no color
1st color:
Andon
2nd color:
Battery
DX80 Q45 remote RF actuator

Integral pushbutton & LED indicator
GA 05
Andon Rope-pull Actuator

Objective: Improve the Andon Rope-Pull actuator and
local indicator.
Type:
Andon
Solution: Banner K50 series indicator with integral
indicator on a unique rope-pull bracket.
Value: The K50 light / switch is commonly used in
other GA applications.
Its proven to be a cost-effective reliable device; highly
visible LED indication, self-contained with no moving
parts.
Plug & play with the existing I/O block architecture.
Note: Activating the rope-pull causes the bracket
mechanism to pivot in front of the non-contact sensor.
Typical operation: when activated, the sensor signal is
sent to the host via pin 4. The host controls the LED
indicator via pin 2.
Options: Various K50 colors are available.
Other actuator type include: ergo grip style and
remote RF activation.
K50 Indicator
with integral
FF50 sensor
Rope-pull
bracket
GA 06
Andon Add-on
Objective: Add additional indication to the existing
Andon light / switch to improve visual awareness.
Type:
Andon
Solution: Banner EZ-LIGHT LED indicators
Value: A simple plug & play solution to improve the
visual indication on the assembly line.
Note: The original positioning of the Andon light /
switch is determined for the best positioning of the
Rope-pull so its easy to access.
But in some cases the light is difficult to see at a
distance a second indicator can be easily added with
a common Y cord and positioned in a better location.
K50L with its dome shaped illumination surface is the
preferred indicator style.
The existing Andon light / switch may use I/O block

architecture with the host signal on pin 2.
Options: K50L models are available in various
colors.
Specific K50L models with more than the
standard number of LEDs (per color) improve
visibility.
GA 07
Part Picks
Objective: Provide operator guidance with pick lights
with sensor feedback to confirm the correct item was
picked.
Category: Operator Guidance / Assist
Type:
Pick to Light
Solution: Banner Pick-to-Light devices: Indicators with
integral ergonomic sensors.
Value: Improved through-put time and accuracy.

Pick Lights simplify the process and helps minimize
training requirements.
The single-point sensor types provide a lean solution.
Note: Used for both line-side and kitting part picks.
The array types cover a large area in front of
the bin.
The optical FF sensor (100mm range) reliably

detects black or dark colored gloves.
The capacitive Touch sensor reliably detects the hand
even when thick Kevlar gloves are being worn.
Options: Indicator size, Number of colors, Internal
logic, Sensor types.
FF100 optical sensor detects dark gloves
Touch ergo sensor
Touch ergo sensor with thick gloves
GA 08

picked.
Type:
Pick to Light

Note: PVA is an opposed style with emitter and
receiver which provide dual-sided pick light indication.
Options: PVA is available in four heights.
Various mount options as well as protective covers are
available.
GA 09

Objective: Apply lean mistake proofing array
sensors with pick lights to assist the operator in
selecting the correct parts.
Type:
Pick to Light
Solution: Banner Part Pick array devices.
Value: Array devices cover a wide area so the
operator is reliably detected regardless how they reach
in and remove the part form the bin.
Pick to Light simplifies the process and helps minimize
Notes: This installation uses PVA (opposed mode)
series with heavy-duty protective covers
recommended for picking larger metal parts that might
strike the array.
Options: PVD or PVL series operate in either diffuse
or retro reflective mode for single-sided sensing.
GA 10

Objective: Provide operator guidance for part
selection with pick lights and provide a signal to
confirm the correct item was selected.
Type:
Pick to Light
Solution: Banner VTB series: Indicators with integral
yoke / finger-swipe sensor.

Notes: VTB devices are robust, sealed IP67 and use
high quality LEDs.
Options: Colors, logic & connectivity.
Mounting and protective covers.
GA 11
Line-side Status Indicator

Objective: Upgrade the indicators to improve visibility
and simplify the installation.
Type:
Visual Management
Solution: Banner customized TL50 series indicators.
Value: Pre-assembled, sealed indicators with
improved visibility (no colored plastic windows) and
connectorized for a simple plug & play solution.
Note: When not energized, the surface is plain without
color; when off, stray ambient light doesnt create
confusion.
Once energized the colored LED create a high contrast
indication.
Options: Per customers request: TL50 with dual
pigtail QDs, each 2 m in length, I/O block compatible,
and kitted with brackets.
OFF
ON
GA 12
Line-side Key Switch

Objective: Improve the key switch to a more compact
lower cost device.
Type:
Pick to Light
Solution: Banner customized K50 series.
Value: Cost-effective solution in the common K50
form-factor.
Note: This 3 position key switch model has no
illumination, the dome is a solid yellow color.
The 1 m pigtail QD is I/O block compatible.
Options: Per customers request: Illuminated models,
additional key movement types.
GA 13
Over-travel Indicator
Objective: Provide a lean solution for the conveyor
over-travel indicator.
Type:
Visual Management
Solution: Custom Banner TL50 series tower lights
with multiple pigtails for I/O block connectivity.
Value: Dramatic lowering of costs and greatly
simplified installation. Previously, an indicator needed
to be mounted on an enclosure for the field
terminations.
Note: The indicator & horn energize if either
mechanical limit switch is activated. The Safety I/O
block will provide power only.
Options: Per the customers request: the first pigtail
QD (branch 1) has male connections for the I/O block.
The other two pigtail QDs are both female to connect to
the switches. Model: TL50YAQP-10822
3 Pigtail QD
Limit Switch 2
Branch 3
Limit Switch 1
Branch 2
Safety I/O Block
Branch 1
Label
LS2
LS1
SI
GA 14
Indicator Retrofit
Objective: Improve the older indicators with
contemporary devices that are easier to install,
maintain and improve the visibility.
Before
After

Type:
Visual Management
Solution: Banner TL50 retrofit solutions.
Value: Indicators with industry standard M12 QDs, or
customized to suit the existing equipment.
Note: Retrofit brackets allow easy drop-in
replacement.
Options: Per customers request: connection details,

elevated mounting hardware and kitted solutions.
model
SMBAMSTL50M30
retrofit bracket
GA 15
Bulk Part Picks

selection with highly visible pick lights and an
ergonomic sensor for system feedback.
Type:
Pick to Light
Solution: Banner K50 series: indicators with integral
sensor.

Notes: K50 devices are robust, sealed IP67 and use
high quality LEDs. The 50 mm dia indicator provides
excellent visibility.
The integral LP optical sensor is aligned on a retro
reflective target up to 2 m distance; the operator
interrupts the beam for actuation.
The integral FF100 optical sensor provides a 100 mm

sensing zone for the operator to wave their hand by.
Being a single-sided sensor, no alignment is required.
Options: Mounting brackets and protective covers.
Protective cover
GA 16
Bulk Part Picks

Objective: Provide various solutions for the station:
array for part picks, ergo actuators plus sensors for
container present and door open.
Category: Operator Assist
Type:
Pick to Light
Solution: Banner arrays, ergo actuators and sensors
Value: More sensors = more solutions.
Notes: The arrays allow a complete passive
interaction from the operator since they may require
two hands to pick the larger parts.
The VTB is an ergo actuator to signal when more parts
are required.
The sensors verify both fully closed or open door.
PVA opposed-mode
VTB
GA 17
Kitting Part Picks

selection with pick lights and provide a signal to
confirm the correct item was selected.
Type:
Pick to Light
Solution: Banner Pick Light devices: Indicators with
integral sensor.

Note: All K50 devices are robust, sealed IP67 and
use high quality LEDs.
Options: Colors, Connectivity, Mounting.
GA 18
Kitting Part Picks

Objective: Provide operator guidance for Kitting part
picks when building more than one kit at a time.
Type:
Pick to Light
Value: Lean system flexibility and value can be
increased by combining standard discrete products.
Note: The capacitive touch sensor reliably detects
the hand even when wearing gloves.
In kitting applications, the touch sensor provides a
kinesthetic aspect.
Operator feedback is improved when the device
provides an automatic acknowledgement by changing
color.
Options: Models, Indicator size, Number of colors,

Internal logic, Sensor types.
Standard discrete products with simply modifications.

Dual pigtails and unique laser
etch contributes to a
successful lean solution.
Prototype example: 3 independent bi-color indicators with
integral touch sensor reduces the pick device costs and
reduces associated cords and I/O blocks by 1/3.
GA 19
Part Removal
Objective: Verify the part has been removed and
placed in the collection bin.
Type:
Part Put
Solution: Banner LX sensor arrays.
Value: Parts made of any material -metal or plasticare detected as they fall through the optical array. The
part to be verified may pass through at high speeds and
always be reliably detected.
Note: LX series standard models include an integral
output pulse stretcher with a 5 msec duration - typically
used with higher speed automated processes. For
general assembly applications, the integral output pulse
stretcher with a 500 msec is typically used.
Y-Cords simplify the installation and allow a single
home run cable to the control system.
Options: An additional Y cord allows an EZ-Light easy
indicator addition for local feedback that the past has
been detected.
GA 20
Tool Nest Sensor / Indicator

Objective: Indicate when the unique tool is required
for the process and verify with feed-back confirming it
was removed from its tool nest.

Type:
Flex Manufacturing
Solution: Banner LX series part presence arrays and
K50L series indicators.
Value: Tools may have irregular shapes and
placement in the nest may vary; all types will be
detected with the array sensor and tool positioning isnt
critical.
Note: Select LX series models operate in light

operate to provide a signal when the tool is removed
from the tool nest.
Options: The K50L indicator can receive its signal on
pin 2 and the sensor sends its signal on pin 4 to allow
a single I/O block port may be used.
GA 21
Vehicle Detection
Objective: Improve the Bar Code trigger signal with a
robust sensor solution for the detection of vehicle and/or
pallet thats not affected by vehicle color.
Category: Traceability/ID
Type:
Solution: Banner ultrasonic sensors
Value: Specific models have 2 independent set points
and could be used to detect both vehicle and pallet in the
single sensor, eliminating the need for a sensing device to
detect the pallet.
All models have push-button teach and include set-point
window capabilities to increase the flexibility of the
device for a range of application parameters.
Sensor Power
Indicator
Target Signal
Strength Indicator
Note: Longer range models (to 8 m) are mounted above

the vehicle to detect vehicle roof and/or pallet.
Options: Different ranges plus analog versions.
Model QT50U
range to 8 m
Output B
Pushbutton
Output A
Pushbutton
Output B
Indicator
Output A
Indicator
Vehicle detect A
Pallet detect B
Output A
Vehicle present
Output B
Pallet present
GA 22
Vehicle Detection
Objective: Improve the sensing of the vehicles
with a more robust solution.
Type:
Value: Single-sided sensor that ignores color
differences and has easy to use, yet precise
sensing window set-up options.
Notes: Not impacted by the air movement created
by the large fans that are used seasonally.
Options: This installation used Banner series
Q45U. Current models have improved
performance and lower costs.
T30U series
GA 23
Glass Detection
Objective: Improve quality in the glass cell by
replacing the mechanical-contact switches
with non-contact sensors.
Type:
Glass Cell
Value: Non-contact highly reliable switching,
regardless of transparency.
Note: Ultrasonic sensors are not affected
by surface color variations.
Push-button teach simplifies the sensing
window set-up procedure.
Options: This installation used Banner series
Q45U. Current models have improved
performance and lower costs.
T30U series
GA 24
Glass Inspection
Objective: Implement multiple error proofing solutions
in the glass cell to resolve: robot part position, verify
presence of the electric connector and verify the
presence of the window tint.
Type:
Glass Cell
Solution: Banner photoelectric sensors.
Value: More sensors, more solutions.

Note: Opposed mode fiber optics detect the windows
edge for robotic part positioning as well as verifying the
presence of the tinted window.
The opposed mode fiber controller R55F
series is push-button teach for simple set-up.
The LED signal-strength bar graph provides precise
indication for simple set-up and maintenance.
An adjustable field sensor detects the cable.
The adjustable field sensor Q60 series is allowable
with different light source types to suit the application
parameters.
Options: Q60 protective cover bracket are available
recommended when mounted near material handling
racks.
R55F
Q60
AMS
GA 25
Glass Tint Verification

Objective: Verify the presence or absence of tint in
the window for manifest comparison.
Category: Error Proofing / Quality
Type:
Glass Cell
Solution: Banner light intensity sensors.
Value: Banners light intensity sensor discerns no
tint, single or double tinted glass and are self
contained devices with simple push-button set-up.
Notes: In the image to the right, the robot places
the glass on a fixture; the sensor is mounted below,
aimed upward where the basic plant lighting from
above serves as the light source.
Multiple sensors can be used to generate a positive
signal when tint is detected, or when no tint is
present.
Options: For greater resolution or critical set-up,
model DF-G1 fiber controller provides a digital
display and additional configuration options.
To external condition the ambient light, a diffuser
could be placed in front of the plant lighting to
eliminate hot spots.
For more challenging light intensity comparisons, a
vision back light provides an extremely even light
source.
Mini-Beam series
LED Back Lighting
GA 26
Vehicle Transfer Lift

Objective: Improve the sensor that detects the
position of the vehicle on the locating pins.
Type:
Vehicle Transfer
Solution: Banner ultrasonic sensors
Value: Ultrasonic detection allows window type
sensing fields which allows greater flexibility in position
detection.
Push-button teach allows simple set-up.
Note: Ultrasonic sensors are self-contained and I/O
block compatible.
S18U
GA 27
Vehicle Position
Objective: Verifying vehicle positioning on the
conveyor.
Type:
Part Position
Value: After the previous transfer, proper position is
verified prior to further inspections.
Note: Model Q60 adjustable field with background
suppression is available with either laser
or LED light source.
Options: Brackets for basic installation as well as
brackets that also provide mechanical protection are
available.
Q60
AMS
GA 28
Vehicle Position
Objective: Monitor the position to the vehicle relative
to its location within the assembly footprint to
accurately communicate torque for traceability.
Type:
Part Position
Solution: Banner laser sensors
Value: Model LT3 time-of flight laser is a robust
device with simple push button set-up.
Note: The LT3 in retro-mode with analog
output provides a linear output over the length of
its sensing range.
Maximum range is 50 m.
Options: Brackets for basic installation as well as
brackets that also provide mechanical protection are
available.
LT3
AMS protective bracket
AMS basic bracket
GA 29

Objective: Reduce downtime due to overheating
bearings by providing early warning with non-contact
sensing.
Preventative maintenance will periodically verify the
correct grease level in the bearings but unexpected
down-time due to bearings over-heating and seizing still
occurs.
Category: Error-proofing / process
Type:
Conveyance / Drives
Solution: Banner T-Gage temperature sensors.
Value: The T-Gage sensor passively detects the
temperature of the surface from the IR emissions.
Note: Multiple T-Gage sensors are mounted on the
conveyor line positioned to sense the roller bearings as
the carrier passes. As the roller bearing fills the FOV,
the nominal bearing temp is detected.
If the bearing grease amount has diminished, the

temperature is much higher, sensor reading spikes and
the output is detected.
T-Gage is a self-contained sensor which is I/O block
compatible.
Options: T-Gage can be connected to a Banner
wireless Node and have its I/O status -either analog or
discrete- communicated across the plant.
T-Gage
GA 30
AGV Communications
Objective: Wirelessly communicate the status of the
AGV to the remote control system.
Monitor devices on the AGC such as switch status or
on the AGV such as on-broad diagnostics to verify
proper operational parameters.
Category: Error-proofing / process
Type:
AGV / AGC
Solution: Banner wireless networks.

Value: Improve the process with 100% quality
inspections and continuous monitoring.
Awareness to potential issues is immediate; response
time is improved and costs minimized.
Notes: Wireless Nodes may communicate I/O status
from common plant devices, either discrete or
analogue.
Data radios wirelessly transmit & receive serial or

Ethernet communications.
GA 31
Part ID / Laser
Objective: Identify the actual build and confirm
to the manifest.
Verify presence of either: block heater
connector or cover plug.
Benefit: Cost-effective solution.
Note: Q60 series provides accurate switching
repeatability with precise background
suppression.
The laser version provides a small concise
beak for small targets.
Connector
Cover Plug
GA 32
Position Mapping / Laser

Objective: Confirm the coordinates of the
empty pallet prior to robot loading parts.
Solution: Banner L-Gage
Benefit: Cost-effective solutions.
Note: Robot makes an initial sweep of the
empty pallet for laser gauging, for accurate
placement of finished parts.
BOM: Please contact Banner.
GA 33
Banner Engineering Corp.
Banner
9714Engineering
10th AvenueCorp.
North,9714
Minneapolis,
10th Avenue
MNNorth,
55441 Minneapolis,
Phone: 1.888.373.6767
MN 55441 Phone:
www.bannerengineering.com
1.888.373.6767 www.bannerengineering.com
Interior Parts & Sub Assemblies Contents

Pneumatic Moving Tool
DX80
IP02
System Status Indication
EZ-LIGHT
IP03
IP 01
Pneumatic Moving Tool

Objective: Incorporate 100% error proofing to the
pneumatic tool to provide quality verification.
Segment: Interior parts
Category: Error-Proofing / Process
Type:
Adhesive
Solution: Banner wireless I/O.
Value: Equipment parameters are now checked
100% every cycle; a wireless I/O option simplified the
upgrade and was cost-effective.
Notes: The pneumatic tool moves with the process;
a cabled solution would be more complex, expensive
and take longer to install.
Options: Today an further improvement could be by
using the Q45 wireless devices; smaller and several
feature integral sensor types.
IP 02
System Status Indication

Objective: Reduce complexity and lower costs by
improving the visual management that displays
system status.
Before:
Segment: Interior Parts

Type:
Visual Management
Solution: Banner EZ-LIGHT LED indicators.
Value: Continuous visibility improvement with a
robust device that has common industrial mounting
and connectivity.
After:
Note: The previous solution required an enclosure

and used light duty panel mount indicators.
The new solution can use simple brackets with
labels.
EZ-LIGHT use high quality LEDs and feature IP67
housings and are tool-mountable.
Options: Many housing styles, colors and

connectivity.
K30L & K50L IS Certified models suitable for
hazardous area are available.
EZ-LIGHTs
AMS Bracket with legend.
IP 03
Paint Contents
Bearing Temperature Monitoring
Conveyor Link Inspection
E-coat Dip Tank
Color Match
Bar Code Reader
Model ID
Collision Warning
Vehicle Position
Paint Purge Verify
Clear Object Detection
High Temperature Oven
Hazardous Environments
DX80
Vision
Vision
Vision
Vision
Measuring Array
P/E Beam Break
Ultrasonic
P/E Expert
P/E Expert
P/E Fibers
P/E Fibers
P/E IS
P02
P03
P04
P05
P06
P07
P08
P09
P10
P11
P12
P13
P14
P 01
Bearing Temperature
Objective: Implement full-time continuous monitoring
of temperature & vibration on bearings & couplers on
main drives and reduce the required manual inspection
& reporting procedures.
Segment: Paint
Type:
Conveyance / Drives
Solution: Banner Wireless I/O
Value: The ability to remotely monitor motors with a

cost effective, industrial radio allows for
a more comprehensive review of equipment.
Trending analysis provides an early warning for
pending drive maintenance requirements preventing
unexpected down-time or other equipment failure.
Cost savings in reducing the manual PM tasks.
Notes: Nodes may accept a wide range of digital
and/or analog signals from thermocouple, or other
temperature and/or vibration sensors.
Options: Banner T-gage series non-contact IR
temperature sensors.
T-Gage
P 02
Conveyor Link Crack Inspection

Objective: Reduce downtime due to unexpected
chain link breakage with early-warning detection of
developing cracks in the link.
Segment: Paint
Type:
Conveyance / Drives
Solution: Banner vision sensors
Value: Cracks are detected before the link breaks;
unexpected down-time can result in 12 wasted hours
downtime for process cooling, repair then start up.
Once detected, the problem can be addressed when
the production schedule permits and the line positioned
so the damaged section is easy to access.
Notes: This installation used 2 area lights on either
side of the vision sensor.
The image with a normal link is a plain gray surface,
however when a crack is present, the contrasting
image is easily detected.
A Banner sensor serves as a trigger which is
connected directly to the camera.
Options: Either P4 smart vision sensor or iVu
image sensor could resolve this application.
P4
iVu
P 03
E-coat Dip Tank

Objective: Verify the conveyor fastening is correct
before and after the vehicle cycles through the dipping
process.
Segment: Paint
Type:
Vehicle Transfer
Value: Past problems when the fasteners were not
properly fixtured before the process resulted in the
body disconnecting from the conveyor and becoming a
floater.
Verifying after the process ensures the clamps have
released prior to the automation attempting to lift and
transfer the body.
Prior to verification, both cases have caused downtime
along with product and equipment damage.
Notes: The P4 smart vision sensor measures the
position of the clamp relative to the body.
The sensor is forgiving of the movement and other
mechanical tolerances of the conveyor.
IP68
P 04
Color Match
Objective: Verify that the color on the vehicle
matches the build manifest and correct errors.
Segment: Paint
Type:
Color
Value: 100% automatic inspection increases quality
and saves additional costs.
Notes: The build manifest triggers a color-specific
set of parameters to be sent to the camera. A
pass signal verifies it is the correct color.
Inspection area requires some shielding from
ambient light due to the subtle color differences.
The dual lights on either side of the reflective
material create a cloudy-day lighting method.
Options: New lighting options from Banner would
simplify this lighting arrangement.
P4 smart vision sensors
IP68
IP20
P 05
Bar Code Reader

Objective: Implement a more robust bar code reader
that reliably reads all 2D & 1D laser etched, stamped
or printed on labels.
Segment: Paint
Type:
BCR / OCR
Value: A robust reader with easy set-up, capable of
reading both 2D and 1D bar codes.
Notes: Lens and light selection impacts distance to
target.
The iVu is configured via its LCD touch screen either
integral or remote.
Options: P4 BCR is available in either IP68 or IP20
housing; iVu BCR is rated IP67.
P4
IP68
P4
IP20
iVu
IP67
P 06
Model ID
Objective: Verify the model based upon body
structural differences.
Segment: Paint
Type:
Model ID
Solution: Banner measuring light arrays.
Value: Independent verification in the paint shop
improves error reduction and reduces costs.
The measuring array solution is simple and
robust; the emitter and receiver creates an opposed
mode system.
Notes: On this line there are 32 variations to identify.
A Banner sensor is used to trigger the inspection.
Measuring Light Arrays
P 07
Collision Warning
Objective: Detect if a door is open and stop the line
prior to damaging the vehicle.
Segment: Paint
Type:
Part Presence
Value: Simple, cost-effective solution.
Note: Opposed-mode or polarized retro sensors

are commonly used.
P 08
Vehicle Position
Objective: Implement sensors that perform better
in multiple Paint Shop applications.
Segment: Paint
Category: Life Cycle performance & cost
Type:
Vehicle Position
Value: QT50U reliably ignores the ionized water
flow but detects the presence of the vehicle,
controlling the flow and saving energy and reducing
waste.
Very robust sensing performance regardless of the
targets surface color & finish.
Notes: In the wet spray environment, the model
QT50U ignores all of the water spray.
In order to intentionally false trip the sensor, it
would need to be positioned directly in front of the
largest and most concentrated water flows and the
sensing window taught to detect its presence.
Options: Pigtail QDs help minimize the overall
space where the sensor can be mounted, in
addition, they also provide a built-in service loop and
help reduce mating cordset types.
P 09
Paint Purge Verify

Objective: Provide 100% inspection to ensure the fluid in
the lines has changed with the purge cycle and confirm it
is either paint or solvent.
Segment: Paint
Type:
Color
Solution: Banner expert sensors.
Value: Low contrast detection is easily achieved with
push-button expert set-up.
Note: Fiber optics use the medium to complete the
optical path to detect the contrast difference in the two
solutions.
P 10
Clear Object Detection

Objective: Inspect to detect the presence of plastic
sheeting on the vehicle.
This paint line has a two-tone paint option. The
plastics sheeting needs to be present during the
process.
Segment: Paint
Type:
Part Presence

Value: Low cost error-proofing with simple set-up
to improve error-reduction and lower costs.
Note: A retro-reflective model designed for
clear object sensing reliably detects presence of the
plastic.
P 11
High Temperature Oven

Objective: Verify the vehicle frame is properly
positioned on the overhead conveyor through-out the
high temperature process.
Segment: Paint
Type:
Part Presence
Solution: Banner high temperature fiber optics.
Value: A derailment will now be detected and the
location identified immediately.
Note: The two opposed-mode high-temp fiber optic
cables are both 7.6 m / 25 in length with L16 lenses.
The Q45 sensor is mounted remotely in a location
where the LED bar graph which displays the sensor
performance & optical beam strength can be easily
viewed.
Options: Lens accessories increase the optical
strength increasing the range and simplify alignment.
Fiber with threaded tip
Optional L16 Lens
P 12
Objective: Detection of vehicle presence in
hazardous environments.
Segment: Paint
Type:
Part Presence
Solution: Banner fiber optic sensors.
Value: The metal clad fibers allow a robust costeffective sensing solution.
Note: Two fibers are used in opposed-mode inside
the booth, with the associated (general purpose)
sensors located outside of the environment.
Options: Namur sensors intended for mounting
inside the hazardous environment.
P 13
Objective: Detection of vehicle presence in
hazardous environments.
Segment: Paint
Type:
Part Presence
Solution: Banner IS certified photoelectric sensors.
Value: Greater optical beam strength performs
reliably in the heavy spray environment and simplifies
alignment.
Note: SMIxxx series with remote barriers are approved
for IS environments.
Options: SMI912 is available in various optical modes.
SMI30 series are opposed mode sensors and provide
greater range for penetrating heavy air-borne spray.
Maximum ranges:
SMI912
60 m / 200 ft
SMI30
140 m / 460 ft
P 14
Powertrain Assembly
O-Ring Presence & Position
Keeper Inspection
Valve Stem Spring Inspection
Cylinder Head Clip Inspection
Fastener in Tool Inspection
Spark Plug Verify
Visual Inspection
Valve Seat Inspection
Valve Seat
Part Picks
Part Pick & Part Put
Model ID Indication
And-on Ergo Actuator
Structural Adhesive Bead
Part Presence/Photoelectric
Part Position/Laser
Small Part Detection
Bin Part Pick Single Point
Machine Thread Verify/Laser
iVu Image Sensor

P4 Smart Image Sensor
L-Gage
Arrays
iVu Image Sensor
iVu Image Sensor
Expert Sensor
P4 Smart Vision Sensor
Pick-to-Light
Pick-to-Light
EZ-LIGHT Indicator
VTB, K50
Fiber Optic Sensor
LT3
Fiber Optic Sensor
EZ-LIGHT Indicators
Laser Diffuse Sensor
PA02
PA03-PA04
PA05
PA06
PA07
PA08
PA09
PA10
PA11
PA12
PA13
PA14
PA15
PA16
PA17
PA18
PA19
PA20
PA21
PA 01
O-Ring Presence & Position

Objective: Upgrade the performance of the error
proofing sensor to verify presence of the o-ring.
Currently there are bad parts that pass and good parts
that fail.
Segment: Powertrain Assembly
Type:
Part Presence
Value: Reliably verifies the presence of the O-ring. The
part can vibrate or move anywhere within the field of
view with robust positive verification.
Extremely easy to set up. No computer is required.
Note: The original sensor connected via M12 QD to a
common I/O block. iVu accessory cords allow a direct
plug & play retrofit solution with no changes to the
existing logic.
Options: The iVu model installed in this application has
the integral LCD touch screen; a remote display would
allow convenient set-up outside of the safety fence.
iVu Image Sensor
Remote LCD touch screen
O-ring
PA 02
Keeper Inspection
Objective: Verify the presence and orientation of
the two keepers.
Type:
Part Presence / Orientation
Value: 100 % quality inspection with a simple to
use vision device.
Note: The two keepers must be orientated correctly
to pass.
Options: This application uses the P4 smart vision
sensor; the iVu image sensor could also be applied.
PA 03
Keeper Inspection
Objective: Improve quality by verifying both
keepers are present and properly nested.
Type:
Part Presence / Orientation
Solution: Banner sensors.
Value: Several viable Banner solutions.
Note: The first solution uses laser emitter and receiver

for a very precise detection of the plunger's position - the
correct height verifies the correct position / nesting of the
keepers.
The second solution uses expert optics in a selfcontained sensor to ensure the
two keepers are present and properly positioned.
Due to the shape of the keepers, the difference to the
sensor between the thick side up (correct) versus thin
side (incorrect) is easily discernible.
PA 04
Valve Stem Spring Inspection

Objective: Verify correct placement of the spring
on the valve stem assembly.
Type:
Value: 100 % quality inspection.
Note: Selection and placement of lighting is critically

important.
Options: This application uses the P4 smart vision
sensor; the iVu image sensor could also be applied.
Garter Spring
PA 05
Cylinder Head Clip Inspection

Objective: Improve quality and verify the cylinder
head clip presence and position with a non-contact
solution.
The existing LVDT contact sensor does not maintain
its resolution over time.
Type:
Solution: Banner vision or laser gauging solutions.

Value: Several viable Banner solutions.
Note: By using a vision solution, the existing
mechanical motion for the LVDT can be eliminated.
If a laser gauge is used, it could maintain the
existing mechanical motion; the L-Gage would be
mounted off the motion, gauging the position of a
target on the slide.
Pass
Fail
Cylinder Head Clip
PA 06
Fastener in Tool Inspection

Objective: Improve quality production and reduce
downtime by verifying that no fasteners are in the tool
once the cycle is complete and its in the raised / home
position.
Type:
Solution: Banner array sensors.
Value: Simple robust solution.

Note: LX arrays are available in various lengths.
PA 07
Spark Plug Verify

Objective: Verify the spark plug selected
is the correct type.
Type:
Benefit: 100% inspection ensures high quality.
Note: This application used a 16 mm lens,

mounted 1.8 m away, with diffuse fluorescent
lighting.
Options: Today the iVu image sensor would be a
likely improvement due to device simplicity and
lower cost.
PA 08
Visual Inspection
Objective: Provide a remote display to improve
ergonomics for the manual assembly task.
The chain has a specific link color-coded that needs to
be positioned to the highlighted position (both divot &
paint spot) on the sprocket, but the positioning is
awkward to the operator to see.
Type:
Visual Management
Value: The iVu with remote display provides a simple
and low cost solution.
Note: The divot on the sprocket is where the unique
link on the chain needs to be positioned.
Divot with yellow paint mark on Sprocket
Originally there was a (yellow) paint mark added to the

divot to help improve visibility - which can now be
eliminated.
The positioning of the sprocket on the assembly is
such that its awkward for the operator to ergonomically
view the correct positioning.
Unique link on chain
PA 09

Objective: Implement 100% error proofing inspection
to verify the presence of the valve seat in the assembly.
Type:
Value: Quality assembly is verified.
Note: Convergent mode optics focus 100% of the

sensors detection area to the small surface required in
this application.
The Expert aspect allows simple push-button teach setup.
Options: This application ran for two years, then was
upgraded to Banner vision to additionally detect cracked
or inverted valve seats.
valve seat
absent
valve seat
present
Expert type optical sensors
PA 10

Objective: Upgrade the error proofing system to verify
the presence and orientation of the valve seat in the
assembly and inspect the surface for any defects.
Type:
Value: Quality parts (no cracks) and assembly is
verified.
Note: Lighting selection and positioning is critical.
PA 11
Part Picks
picked.
Type:
Pick to Light

Pick Lights simplify the process and helps minimize
Note: Used for both line-side and kitting part picks.
Options: Indicator size, Number of colors, Internal
logic, Sensor types.
FF100 optical sensor detects dark gloves
Touch ergo sensor
Touch ergo sensor with thick gloves
PA 12
Part Pick & Part Put

Objective: The part being assembled needs the
correct shim to be picked from one of 40 bins and
correctly placed on the one of 24 assembly positions.
Type:
Pick to Light
Solution: Banner LED indicators.
Value: Low cost operator guidance solution.
Note: The 30mm indicators are mounted on the front
of the rack to assist the assembly person picking the
shims, and the trolley cart has 18mm indicators to
guide the operator where to place them.
Options: Indicator color, housing type & size.
T30
M18
PA 13
Model ID Indication
Objective: Provide operator assist with
visuals that ID the model present and lower
installation and maintenance costs.
Solution: Banner EZ-LIGHTTM indicators.
Benefit: The LED indicators in IP67 sensor
housings can be mounted anywhere and are
I/O block pluggable.
Note:
AMS series brackets mount directly to
Unistrut.
AMS series brackets are available in models
that provide space to mount a legend or tag.
BOM: Please see the selection guide.
PA 14
Andon Ergo Actuator

Objective: Improve the Andon actuator / indicator
device and lower costs.
Segment:
Category:
Type:
Powertrain Assembly
Error-Proofing / Quality
Andon
Solution: Banner K50 series indicator with integral

indicator in an ergo grip accessory.
Value: The K50 series is commonly used in
other applications.
Its proven to be a cost-effective reliable device; highly
visible LED indication with integral sensor.
Plug & play with the existing M12 QD system.
Note: The device is suspended by its cable.
Typical operation: when activated, the sensor signal is
sent to the host via pin 4. The host controls the LED
indicator via pin 2.
Options: Various K50 colors are available.
Other Andon actuator type include: rope-pull and
remote RF activation.
Other ergo actuators include: VTB; optical
non-contact.
VTB yoke actuator & indicator with bracket
K50 pushbutton and indicator with ergo grip
PA 15
Structural Adhesive Bead

Objective: Provide 100% inspection of any dispensed
material: structural adhesive, mastic or sealant.
Export total inspection analysis via Ethernet IP for
traceability purposes.
Segment:
Category:
Type:
Bead 100% inspection

Value: 100% inspection ensures higher quality.
Notes: P4 smart vision sensors include many different
tools for a wide range of common error
proofing applications.
When in Setup mode, the ROI is created along the bead

path for bead location. The inspection parameters are
configured for pass/ under/over bead width, plus skips etc.
During Run mode, pass/under/over analysis is color-coded.
PA 16
Part Presence / Photoelectric

Objective: Detect low profile part presence on the
conveyor.
Solution:. Banner fiber optic sensors.
PA 17
Part Position / Laser

Objective: Increase lehr through-put and improve
the sensing devices to simplify set-up and
minimize downtime.
Solution: Banner laser sensors.
Benefit: The additional switch points provide better
part location information, which allows an increase
of the number of parts in the oven.
Note: Single-sided sensing eliminates the need for

opposed-mode alignment previously a twoperson task.
While this is a high temperature environment inside
the lehr, the LT3 is a longer-range device, so it can
be mounted outside and avoid the temp extremes.
Before: individual high temp fibers with individual
emitter / receiver controllers (lower image).
PA 18
Small Part Detection

Objective: Detect very small or flat parts to verify
they have been either added, removed or ejected
from an assembly process.
Segment: Powertrain
Type:
Part Presence
Solution: Banner Fiber Optics.
Value: Regardless of part size or speed detection
is 100% reliable.
Note: Fibers are available in various shapes to suit
the part size and area where the part may pass;
material of the past is insignificant.
Options: Fibers are available in either glass or
plastic.
Fiber controllers are available in either DC or AC
models.
PA 19
Bin Part Pick / Single-Point

Objective: Provide operator assist with
pick-lights & verify correct bin entry in
assembly with active detection.
Solution: Banner EZ-LIGHTTM indicators
with integral sensor.
Benefit: Indicators help ergonomically and
improve the human movement, so stress is
reduced and quality improves.
Note: The single-point sensor simplifies
the installation and lower costs.
Sensing modes available: fixed-field, retroreflective & pushbutton.
PA 20
Machined Thread Verify / Laser

Objective: Implement 100% inspection and
verify the machined thread is present.
Solution: Banner expert laser sensors.
Note: The laser diffuse sensor has push-button
teach for simple set-up.
PA 21
Stamping
Wireless
Nitrogen Tank Pressure
Wireless
Overhead Crane VFD Monitoring
Wireless
Double Blank Detection/Vision
Vision Sensor
Dispensed Bead Verify/Vision
Vision Sensor
Part Out & Removal/Arrays
Array Sensor
Metal Strip Loop Control/Ultrasonic Ultrasonic Sensor
Transfer Press Gripper
Ultrasonic Sensor
Gripper Part Presence/Photoelectric Photoelectric Sensor
Shovel Part Presence/Photoelectric T18 Sensor
Gripper Part Presence/Photoelectric Photoelectric Sensor
Press Safety Entry/Exit
Safety Light Screens
Stack Level Laser
LT3
Proximity Sensor Cable Replacement
ST2
ST3
ST4
ST5
ST6
ST7
ST8
ST9
ST10
ST11
ST12
ST13,14,15
ST16
ST 01
Proximity Sensor Cable Replacement

Objective: Reduce downtime due to cable failures on
the Tandem Press line.
Segment: Stamping
Type:
Solution: Banner Wireless I/O.
Value: Down-time due to cable issues is eliminated.
Notes: A single inductive proximity sensor is mounted

on the shuttle cage conveyor to verify part presence
and proper seating.
The shuttle cage conveyor moves parts between the
presses. The line is periodically down due to the
proximity sensor cable damage.
A battery-powered Node is mounted on the tool close
to the inductive sensor and communicates wirelessly
with the Gateway positioned with the PLC in the control
panel outside of the safety fence.
Options: Today a more contemporary solution could
be the Q45RD node model and a Namur type induct
sensor.
ST 02
Nitrogen Tank Pressure

Objective: Provide continuous monitoring of the upper
die nitrogen cylinder pressure to provide early warning
of low pressure.
Segment: Stamping
Type:
Process Monitoring
Solution: Banner Wireless I/O & Wireless Sensors
Value: A robust wireless solution is a simple low-cost
solution to provide an early warning of low pressure.
Press lines with large moving parts often suffer from
cable damage and are some are considered high
maintenance; a wireless solution that transmits basic
I/O status is an viable option.
Notes: The press line may have between 2 to 7
cylinders, many with a readout gauge for display only.
Earlier installations (image above right) used a
Banner Node and external battery pack.
The pressure switch with dry contact is wired to the
node; multiple tanks have the pressure switches wired
in series to the node.
Options: Today a more contemporary solution is the
Q45..RD model; self contained with radio & longer life
batteries.
ST 03
Overhead Crane VFD Monitoring

Objective: Provide continuous monitoring of the
overhead cranes VFD for trending analysis by
maintenance.
Segment: Stamping
Type:
Conveyance / Drives
Solution: Banner wireless data radios.
Value: The ability to remotely monitor motors with a
cost effective, industrial radio allows for
a more comprehensive review of equipment.
Trending analysis provides an early warning for
pending drive maintenance requirements preventing
unexpected down-time or other equipment failure.
Cost savings in reducing the manual PM tasks.
Note: The VFD (variable frequency drives) have a
serial data port intended for local diagnostics which
can be sent wirelessly for continuous
ST 04
Double Blank Detection / Vision

Objective: Improve the verification to ensure no double
sheets are processed in the press.
Traditional double blank detectors require critical set-up
to perform properly. These are typically inductive-base
devices that need to make mechanical contact in order
to perform properly. There have been failures with
these devices, and some have been switched to
bypass mode.
Benefit: Improves the verification reliability.
Provides a non-contact solution.
Note: The range of metal thickness, and distance
variables (sensor to target) impact device, lens and light
selection.
ST 05
Dispensed Bead Verify / Vision

Objective: Improve quality by verifying the NVH
bead is within specification.
Be able to verify correct size and identify any
failure: under and over-bead, skips, smears, etc.
Note: The hole opening is approximately 75 mm

diameter.
At the time of inspection, there will be a
metal shaft in the hole which dictates the vision
sensor be mounted perpendicular to the target.
Mounted 1.5 m away and using a 50 mm lens, all
of the other mechanical restraints were respected
and an ideal image captured.
ST 06
Part Out & Removal / Arrays

Objective: Detect the stamped metal
panels exiting the press on the large belt
conveyor, in order to divert them to the
multiple removal stations.
Solution: Banner array sensors.
Note: The target metal may bounce on
the conveyor, so single-point sensors
may not suffice.
A quantity of 35 arrays were used in this
installation.
ST 07
Metal Strip Loop Control / Ultrasonic

Objective: Improve the tension control on the metal
being fed into the process.
Older loop controls lack repeatability and are too
easily affected by ambient noise.
Benefit: Improves the application reliability.
Note: Models with various ranges up to 8m are
available with both discrete and analog outputs.
QT50U series
ST 08
Transfer Press Gripper

Objective: Improve the performance of the
sensors on the grippers that transfer the
metal in the stamping press.
Process: Stamping
Category: Continuous Improvement
Type: Part Presence / position
Solution: Banner remote head ultrasonic sensors
provide a unique sensing solution on grippers.
Value: Precise detection of the edge of the metal
allows verifying the grip will be robust.
Notes: The remote head is mounted to each
gripper/arm.
The ultrasonic controller is mounted on the press
bar and not changed with the die set.
Range: 50 to 250 mm
Sensing Window
ST 09
Gripper Part Presence / Photoelectric

Objective: Improve the gripper sensor and
the application reliability with a simplified yet
robust solution.
Note: The fixed-field optics of this model are
generally the best suited for this type of
application.
ST 10
Shovel Part Present / Photoelectric

Objective: Improve the shovel sensor and
the Transfer Press application reliability with
a simplified yet robust solution.
a)
b)
Fixed-field mode sensors. The 18mm

diameter mount is a common mount method.
Divergent mode sensors; preferred by some
users.

T18 Series
600 Series
ST 11
Gripper Part Presence / Photoelectric

Objective: Improve the gripper sensor and
the application reliability with a simplified yet
robust solution.
Benefit: Cost effective solutions.
Note: The divergent optics of this model
suit the variation in metal surfaces.
The bracket includes a protective cover
created in-house from a piece of Unistrut.
ST 12
Press Safety Entry / Exit

Objective: Provide reliable Category 4 level safety.
Solution: Banner safety light screens.
Benefit: Provides reliable operation in harsh stamping
environments.
ST 13

Objective: Provide robust Category 4 safety on the
destacker.
environments.
ST 14

Objective: Provide robust Category 4 safety on the
destacker.
environments.
ST 15
Stack Level / Laser

Objective: Improve material flow by applying a
sensor to detect when the parts reach a
material call level.
Solution: Banner time-of-flight laser sensors.
Note: The LT3 series provides the longer
sensing distance and small effective beam
required in this application.
The bright laser spot and push-button teach
makes for an easy set-up.
ST 16

Automotive Application Book April, 2014

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Automotive Application Book April, 2014

Загружено:

Авторское право:

Доступные форматы

Sensors

Safety Light Curtains

Body in White Contents

When in Setup mode, the ROI is created along the bead

P4 smart vision sensor

During Run mode, pass/under/over analysis is color-coded.

iVu Plus with

Modification is also much simpler - no more

Robot EOAT Cable Dressing

Wireless Node with:

Robot EOAT Part Presence

FF sensors have no adjustments, and feature

P4 smart vision sensor

Bar Code Reader

Part Sort & Verify

Solution: Banner iVu Image sensor

Options: iVu can provide simple pass/fail signals to

Correct part loaded (pattern match) = PASS

iVu Plus with

Wrong part loaded (no pattern match) = FAIL

Body Panel Gap Measurement

P4 smart vision sensor

P4 smart vision sensor

Weld Cap Inspection

Options: For weld cap profiling inspection, Banner

Tailgate Shape Conformity

Different sensor sizes and ranges with

AMS protective bracket

Model / Style Indicator

Value: Excellent visual indication and simple I/O block

Segment: Body Assembly

Ergonomic Cycle Start

Legacy box solution

Options: VTB series is a general purpose yoke type

K50 with specified laser etch

K50 touch actuator

Tool-mountable E-Stop & Actuators

Value: Basic mounting brackets with connectorized

K50 key switch

Bracket Position Verify

Weld Nut Verify

P4 smart vision sensor

Weld Nuts & Brackets

iVuPlus with remote LCD

Nuts, Baffles & Gaskets

Note: Seven P4 vision sensors are tied into a network

iVuPlus with remote LCD

Nut in Tray Verify

iVuPlus with remote LCD

Clinch Nut Position

Body Parts Contents

Weld Nut Orientation

Weld Nut Orientation

Part Presence & Position - Nut

Nut Thread Inspection

Double Part Detection

Part Presence - Spacers

Note: The robot triggers the image sensor to take

The iVu remote display is mounted on the fence for

iVu Image sensor

Weld Nut Orientation

Solution: Banner iVu image sensor.

iVu Image sensor

Weld Nut Orientation