Assembly and Robotics Solutions

Equipment Monitoring from a Supervisor's Station

Provide at-a-glance machine status indication and send machine status information to a wide range of devices.

Restocking Assembly Stations for a Continuous Workflow

Restock assembly stations before components run out without overstocking.

Optimizing Equipment Effectiveness with Remote Monitoring

Provide instant visual communication across a busy plant floor.

Environmental Monitoring inside a Machine Control Panel

Identify small problems before they become major issues that impact machine performance and uptime.

Wireless Pick-to-Light System for Mobile Assembly Stations

Minimize production errors by providing clear guidance for assembly.

Easy Panels with Multicolor Indicators and Touch Buttons

S22 Pro Series touch buttons and indicators simplify control panel design and improve operator experience and performance. Pro Editor software expands the built-in display capabilities available with the S22 Pro Series, enabling custom displays.

Small Assembly Station Protection with Light Curtains

EZ-SCREEN LS safety light curtains have no DIP switches, feature end-to-end sensing, and can be easily installed with automatic configuration. The use of side mount brackets creates a quick and simple installation with adjustments made from the front side of the EZ-SCREEN LS arrays, saving time during setup. Maximizing machine uptime and reducing repair and replacement expenses helps companies remain competitive.

Dual-operator Robotic Work Station

Safeguarding multiple access points to a hazard with its automatic cascade feature allows up to four light screen sets, of any size and resolution, to be connected in a series saving panel space.

Robotic Palletizer Safeguarding

Banner’s XS26-2 is a flexible, easy-to-use safety controller with an intuitive programming environment, with the capacity to handle current machine processes and the flexibility to add up to eight I/O expansion modules as machine automation grows or changes. A broad spectrum of safety devices are supported, allowing for complex applications to be configured and downloaded to the controller in a minimal amount of time for efficient machine commissioning.

Scalable Safety Control for Large Assembly Processes

Banner’s XS26-2 expandable safety controller is a scalable safety solution that can be tailored for a wide variety of machines, including large scale machines with multiple processes. With the ability to add up to eight I/O expansion modules, the XS26-2 has the capacity to adapt to larger footprint machines with multiple hazards and access points. Several preconfigured safety function and logic blocks are available in the intuitive programming software.

Safeguarding a Robotic Palletizer

Banner’s SC26-2 is a flexible, easy-to-use safety controller with an intuitive programming environment. The programmable safety controller can manage all of the safety devices with one module. The SC26-2 communicates the status of safety devices via Ethernet IP and controls a tower light for visual indication of safety device statuses. The base controller allows eight of the 26 inputs to be configured as outputs for efficient terminal utilization.

Safeguarding a Single-Station Robot Weld Cell

The Banner AG4 Safety Laser Scanner is placed at the base of the hazardous area and “looks out” at the open area. It is programmed via a PC with interface software to guard the area between the physical barriers (the protective zone) and outside the barriers (the warning zone). If the operator or other personnel approach the hazardous area during robot operation, a signal is sent to alert the person that the warning zone has been entered; the robot continues operation during this time.

Robotic Guarding in Work Area without Limiting Access

Safety laser scanners work well for safeguarding applications where user access and protection are equally important. Banner’s AG4 Safety Laser Scanner with a 190º scanning angle fits nearly any shape and can evaluate an operator’s position by range and rotational angle. Its flexibility allows for new safeguarding shapes when work cell dimensions and parameters change.

Heat Stake Machine Safeguarding

In this example, two sides of a heat stake machine require guarding because of separate operator load and unload stations. On each side of the station, two safety light screens protect workers; one with a 48" vertical light screen for area guarding and one with a 12" inclined light screen to guard the point of operation where the tool is loaded and unloaded.

Safeguarding of a Power Press

Banner Engineering’s EZ-SCREEN LS is extremely robust with heavy duty extruded aluminum IP65/67 rated housing, metal endcaps and a recessed window to protect it from collisions related to stock removal and incidental impact.

Safeguarding Access Points to a Depalletizer

An LS Series safety light curtain with a mute arm kit in T-configuration combined with an XS26 Series safety controller is an easy-to-implement solution that protects staff from potential hazards without disrupting the flow of pallets to the depalletizer.

Safeguarding a Robotic Weld Cell

A robotic weld cell is protected on multiple sides by hard guarding. Between work cycles operators must be able to access the weld cell to retrieve completed work pieces and load new material. Used to safeguard access points to the weld cell, an SX5-B6 safety laser scanner can increase machine uptime and productivity.

Monitoring Safety Doors on a Case Packer

Learn how SI-RF Series safety switches can be used to monitor multiple guard doors, ensuring the highest levels of safety, and making it easy to identify and resolve issues.

Vision Sensor to Read QR Codes

iVu Plus BCR Gen 2 with 25 mm Micro Lens replaces hand held barcode readers to collect data from dense, difficult-to-read QR codes on vehicle transmissions. A WL50S high-intensity LED spot light illuminates the target area.

Kitting Operation with Gloves

Banner’s fixed-field K50 indicator detects gloved hands , sensing when operators select the correct parts during the kitting process. The K50 indicator’s logic function is then able to notify the operator that he/she picked correctly by changing from green to yellow—additional colors can be selected to suite to the manufacturer’s preference. The K50’s ability to detect black gloves is especially important for lean manufacturing processes where workers typically wear dark gloves.

Part Pick Verification for Large Bins

To reduce the risk of error in an assembly operation, a one-piece EZ-LIGHT PVD pick-to-light sensor is placed on the top rail of a shelf, looking down on the shelf opening. The PVD is interfaced with a process controller that is programmed to illuminate the PVD on the bin to pick. After the PVD detects that the assembler's hand has entered and left the bin, the controller signals the PVD on the next bin to pick.

Part Pick Indication for Small Bins

To reduce the risk of error in an assembly operation, a one-piece EZ-LIGHT PVD pick-to-light sensor with a 400 mm range is interfaced with a process controller programmed with the correct assembly sequence. The controller makes the PVDs light up in the correct order, to show the assembler which part to pick. After the PVD detects that the assembler's hand has entered and left the bin, the controller signals the PVD of the next bin in the pick sequence to light up.

Long Bin Pick-to-Light

The EZ-LIGHT PVA pick-to-light sensors provide a reliable error-proofing solution for various operation systems. The light indicate to assemblers which items to pick and in which order to pick them.

Improving Production with Pick-to-Light Systems

A Banner wireless solution is a simple way to optimize inventory, reduce errors, and minimize waste. Each Sure Cross Performance Node with I/O Mapping can be equipped with up to six EZ-LIGHT operator indicator lights. The Sure Cross Gateway is conveniently located at a central location where maintenance personnel and management can monitor the parts consumption throughout the site.

Multiproduct Light-Guided Assembly Station

PTL110 pick-to-light devices on a multiproduct assembly station are a highly effective way to prevent errors and speed up build time. The optical sensors on PTL devices detect hands as they pass by, confirming that a pick was made.

Error-Proofing Assembly Applications

Banner’s K50 Series of single-point pick-to-light sensors are a simple, easy-to-use error-proofing solution in assembly applications. In this application, the job light is Green while the job input is active, indicating the correct bin for the next pick. The presence of the assembler’s hand initiates an output change of state, turning the job light red. The job light above the next pick location will then turn Green.

Part Pick Verification from a Wide Bin

The EZ-LIGHT K50 sensor in retroreflective mode indicates that the next part in the assembly sequence is the sunroof. When the operator selects the sunroof from its wide bin, the K50 detects the pick.

LED Lights Illuminate Control Cabinet

Operators access machine systems through the control cabinet and need Intense illumination of the cabinet facilitates for maintenance and management.

Superior Light Distribution with LEDs

American Hoffmann Corporation chose WLB32 LED light bars to illuminate work areas, enclosures and control cabinets, replacing fluorescent light fixtures. The superior light distribution offered by the WLB32 LED lights lights, as well as the ease of installation were key factors in the company's decision.

LEDs Replace Fluorescent Fixtures in Machine Enclosures

• Bright illumination inside weld machine • Comparable in cost to fluorescent lights • Uniform, even lighting

Illuminate Web Inspection Stations with Rapid-Install LEDs

Hermes Abrasives requested lighting to improve inspection capabilities of abrasive products.

Robotic Work Cell Lighting

The energy-efficient WLB72 Basic is bright, easy-to-install, and cost-effective for robotic work cell lighting.

Efficient LED Light Bars Reduce Build Times and Expenses

The company wanted a cost effective lighting solution that would offer brilliant illumination on multiple work stations on large product testing machinery.

Robotic Weld Cell Illumination

Learn how the WLS70 strip light provides bright, even illumination inside robotic weld cells.

Inspecting Small Connectors

An automotive supply company makes a range of vehicle systems. Their seating systems combine structure and design with features that enhance comfort and safety. Weight sensors installed on the underside of the seats work in coordination with vehicle safety systems to determine the size and position of a seat occupant. These factors affect how or if airbags will be deployed in the event of an accident.

Sensors to Measure Movement Range

During assembly, inspections are conducted to measure seat height adjustment, forward and rearward movement, and upright and recline motion.

Sizing, Profiling and Guiding Clear Objects

Banner Engineering has created a special class of EZ-ARRAYs specifically designed to detect clear objects in clean industrial environments. By customizing standard EZ-ARRAY receivers to successfully detect low contrast and operate at a lower sensing range (30 to 1500 mm), Banner has enabled EZ-ARRAY Clear Object Measuring Light Curtains to detect translucent objects such as glass and clear webbing.

Wireless Call for Parts

A system of Banner’s TL70 wireless modular tower lights and K50 touch buttons provides an efficient, easy way to communicate a call for more parts with a forklift driver. When a workstation is almost out of cartons, the operator touches the ergonomic K50 touch button which changes the status on the connected TL70 wireless tower light to red.

Call For Parts

Installing a signal to parts bins is a simple solution to keeping parts bins stocked and the assembly line productive. The EZ-LIGHT K80 Call Light is a large illuminated signal the operator turns on before parts are depleted. The K80 flashes red to signal stocking personnel to replenish bin supplies. In flexible manufacturing environments, operator stations and work cells must allow for quick changes to assembly and manufacturing lines.

Counting Dropping Parts with an LX Sensor

Banner Engineering's LX series part-sensing light screen generates a multi-beam infrared pattern that can detect any item passing through the beams, enabling exceptional sensitivity to small objects. As small parts drop from the feeder bowl into the plastic bag, the LX sensor detects each part and triggers the line to advance when the bag contains the specified number of parts.

Part Loaded Indicator

Before the EZ-LIGHT K50L indicator light was installed, the operator would place a part on the machine and then step out of the work area to check the stack light to see if the part was loaded properly. If not, the operator had to repeat the set-and-check process before initiating the machine's action on the part. Since the K50L was installed inside the workstation, using a simple Y splice, the operator can tell immediately if the part is correctly placed.

Close Proximity Error Proofing on Assembly Line

Banner’s Q4X analog sensor can give operators real-time measurement feedback to verify the part is present and correctly positioned before moving to the next operation. In this application it is crucial that both flanges around the weld nut are properly seated in order to fit correctly in the final assembly. The Q4X’s analog measurement can determine if both flanges are properly seated.

Detecting Black Parts on Black Door Panel

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.

Indicate Robot Positioning

Learn now a manufacturing company used a WLS15 Pro to improve safety in their warehouse.

Remote Monitoring Calculates Machine Run Time

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

Streamlining Call for Parts or Service

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

Communication in a Busy Manufacturing Site

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

Call for Parts

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

Stack Height Detection of Metal Parts

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

Emergency Stopping (end-mounted rope pull)

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

Emergency Stopping (center-mounted rope pull)

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

Calling an AGV for Parts

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

Automatic Storage & Retrieval System

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

Call for Parts (Put to Light)

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

Retrofit for Robotics

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

Call for Parts at a Furniture Manufacturer

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

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