Intelligent Mail Industrial Barcode Reading
The iVu BCR is used in many mail applications to help direct mailers from multiple smaller runs as they are combined into larger ones.
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Applications
Proven Solutions that Keep Operations Running
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End-of-Mail Indication
To detect this mark, use an iVu Series sensor configured for a Match inspection. The sensor detects the end-of-bundle mark, and signals the bundling machine to wrap the finished group.
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Solder Ball Inspection
To verify each integrated circuit, this application uses an iVu Series sensor configured for an Area with Motion application. If the sensor detects a part with missing or damaged solder balls, or if it detects any foreign material, the sensor sends a fail output to the line, and the part is rejected.
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Drilled Holes Inspection
This application uses an iVu Series sensor configured for an Area inspection. When holes are punched, the sensor evaluates all the holes to make sure that they are present and correctly sized. If any are not, the sensor sends a fail output to the line where the part is rejected.
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Label Inspection
To verify each product, an iVu Series sensor is configured for a Match inspection. An image of a good product package is captured. When the inspection is running, if the sensor detects a package with a different or missing label, the sensor sends a fail output to the line, and the product is rejected.
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Part Color Inspection on a Vehicle Door Panel
An iVu Color Sensor identifies RGB values of individual pieces of trim on vehicle door panels and communicates this information over an industrial Ethernet connection to a PLC.
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Orientation Verification
This application uses an iVu Series sensor configured for a Match inspection. It ensures that the music label is face up and within a small rotational tolerance. If the sensor detects a CD that is incorrectly oriented, it sends a failure to the line, and the CD is rejected.
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Electronic Marking Verification
The solution uses an iVu Series sensor configured for a Match inspection. A reference "good" identifier is taught into the sensor. In service on the production line, the sensor detects when a component does not have the correct identifier, and sends a fail output to the line, and the part is rejected.
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Bearing Inspection
The solution involves using an iVu Series sensor configured for a Match inspection to ensure that all the bearings are present for each component that includes the bearing assembly. If the sensor detects one or more missing bearings, it sends a fail output to the line, and the component is rejected.
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Injection Molding Inspection
The solution involves using an iVu Series sensor configured for a Match inspection. The sensor evaluates each plastic bottle and, if the bottle is not well formed, the sensor sends a fail output to the line where the plastic bottle is rejected.
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Combined Inspections Used to Meet Quality Standards
Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.
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Error Proofing Integrated Circuit Chips Loaded into Pocket Tape
• Confirm presence and orientation of IC chips</br> • Sensor performs multiple functions at once</br> • Cost savings and versatility</br>
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Accurate Label Inspection
The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.
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Blister Pack Inspection
To verify each blister in the pack, use an iVu Series sensor configured for an Area inspection. The sensor inspects each blister pack to make sure that each blister contains an unbroken tablet.
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Box Insert Detection
To confirm that each unit includes a product information insert, an iVu Series sensor is mounted above the packaging line. The sensor is configured for a Match inspection, and checks that the product information leaflet is inserted into each package of medication. The leaflet can be placed in any orientation, but must beface up.The sensor can detect 360 degrees of rotation to find the insert.
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Inspection of Stoppers in Vials for Correct Seal
To ensure that a stopper is properly inserted as each vial leaves the filling station, an iVu Series sensor—set up for an Area with Motion application—verifies that the vial has a stopper inserted into its neck and that the stopper is positioned correctly to provide a proper seal on the glass vial. If the stopper is missing or incorrectly positioned, then the sensor sends a fail output to the line.
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Vent Tube Presence on Filler
A high-volume brewery needed a solution capable of detecting spreader washers on the vent tubes as well as loose or missing tubes. However, the movement of the rotary filler and the wet washdown environment made close proximity deployments difficult and the range required for a remote solution could compromise inspection reliability.
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Blemish Detection on Bandage
iVu Series vision sensors are ideal for monitoring materials to ensure that specific quality standards are met. It provides users with complete control and immediate feedback for setup and monitoring of products. It features multiple sensor types, including a blemish sensor, which is the best mode for this application.
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Detecting Tamper-Evident Band Position and Presence
Banner iVu TG vision sensor with multi-point inspections is ideal for detecting and evaluating the position of tamper-evident bands. In this application, the band should be positioned around both the cap and the neck of a bottle. A seal positioned too high, too low, or completely missing would be considered unacceptable. With multi-point inspection, the iVu TG vision sensor can simultaneously detect missing and poorly positioned bands.
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Date/Lot Code Inspection
To verify each package has a date/lot code printed on it, an iVu Series sensor is configured for a Match inspection. An image of the date/lot code is captured. When the inspection is running, if the sensor detects a package without the date/lot code the sensor sends a fail output to the line, and the product is rejected.
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Food Packaging Label Inspection
To verify each box is correct, an iVu Series sensor is configured for a Match inspection with 360 degree rotation enabled. An image of the correct box is captured and when the inspection is running, if the sensor detects an incorrect box, the sensor sends a fail output to the line, and the product is rejected.
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Error-Proofing Loading of IC Chips into Pocket Tape
• Confirm presence and orientation of IC chips</br> • Sensor performs multiple functions at once</br> • Cost savings and versatility</br>
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Date/Lot Code Presence or Absence Detection
An SLM series slot sensor and an iVu Series vision sensor are used to detect bottles passing on the line and to verify that date/lot codes have been correctly printed onto the bottles.
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Label Alignment Inspection
As each salad dressing bottle leaves the label station, an iVu Series vision sensor, configured to use the Match tool, inspects the label, comparing it to a preconfigured reference image to ensure that the label is present and has been correctly applied.
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Inspecting Bottles for Cap Presence and Correct Color
To ensure that product quality standards are met and that product appearance is consistent with the brand, the company must inspect each bottle to ensure that the right bottle cap is present and properly seated.
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Punch Hole Inspection
To verify that the expected number of holes exist on a small metal part that is not rigidly fixed, use an iVu Series sensor configured for an Area with Motion application. When holes are punched, the sensor evaluates all the holes to make sure that they are present and correctly sized. If any are not, the sensor sends a fail output to the line where the part is rejected.
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Part Orientation
An iVu vision sensor inspects nuts exiting a vibratory feeder bowl to ensure that the correct side of the nut faces up. The iVu features an intuitive operating environment that makes it easy for users to quickly apply and support inspections on the device.
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Small Part Inspection in Tough Location
Banner Engineering’s iVu vision sensor inspects presence vent tubes and spreader washers on a busy bottling line. It uses a 50 mm C-Mount lens to extend the working range of the sensor to avoid contact with spray and liquids.
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Correct Label Verification
An iVu TG Image Sensor works well for label verification because it comes with four sensor types, including a match sensor. The match sensor determines whether a pattern on a label matches a reference pattern and if it is correctly oriented. With just the touch of a button—or remotely through a PLC—users can easily teach the iVu image sensor to recognize and match the correct label pattern, requiring no image processing expertise.
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Videos
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![iVu Series Vision Sensors [Video]](/content/dam/banner-engineering/projects/video-thumbnails/i_Vu_Video_Thumbnail-new.psd/jcr:content/renditions/cq5dam.thumbnail.319.319.png)
iVu Series Vision Sensors
iVu Series vision sensors combine the simplicity of a photoelectric sensor with the intelligence of a smart camera. They can be used to monitor parts for type, size, orientation, shape, location, and color or color variations.
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iVu Color and TL50 Pro
Watch the video to see the iVu vision sensor and TL50 Pro tower light in action.
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iVu Plus TG Overview
This tutorial video provides an overview of Banner's iVu Plus TG display and provides instructions regarding the user interface.
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iVu Plus TG Multisensor Inspection
This tutorial is intended to help you set-up and monitor an inspection with more than one sensor. Multisensor inspection is possible if you download the latest Firmware software.
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