Automotive Application Book April, 2014

8/9/2019 Automotive Application Book April, 2014

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Banner Engineering Corp. 9714 10th Avenue North, Minneapolis, MN 55441 Phone: 1.888.373.6767 www.bannerengineering.com

Automotive

Applications

Training & Support

Preliminary

www.bannerengineering.com

pril, 2014

Sensors

Indicators &

Actuators

Safety Controlle

Safety Light Curtains

Vision Sensors

Vision Lighting

E-Stop

Cycle StarTwo Hand Contro

Wireless Sensors &I/O Networks

Work &

Task Lighting


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Body in White Contents

BA 0

dhesive Bead P4 BA02

dhesive Bead P4 BA03

dhesive Patch iVu BA04

dhesive Daub Laser Emitter BA05

obot EOAT Cable Dressing DX80 BA06

obot EOAT Part Presence Fixed Field BA07

odel ID P4, iVu BA08

ar Code Reader iVu BA09

art Sort & Verify iVu BA10

ody Panel Gap Measurement P4 BA11

Weld Cap Inspection R55F BA12

ailgate Shape Conformity S18U BA13

asket Presence Adjustable Field BA14

ut Detection Q45UR BA15

art in Position Adjustable Field BA16

odel / Style ID Indicator TL50 BA17

ool-mountable Indicators EZ-LIGHT Sensor Emulator BA18

rgonomic Cycle Start OTB, VTB, K50, K30 BA19

ool-mountable E-Stop & Actuators OTB, VTB, K50 & K30 BA20

racket Position Verify P4, iVu BA21

Weld Nut Verify P4, iVu BA22

Weld Nuts & Brackets P4, iVu BA23

uts, Baffles & Gaskets P4, iVu BA24

ut in Tray Verify P4, iVu BA25

linch Nut Postion P4, iVu BA26


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Adhesive Bead

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.

bjective: Provide 100% inspection of dispensed

aterials: structural adhesive, mastic or sealant.

xport total inspection analysis via Ethernet IP for

aceability.

egment:

ategory:

ype:

olution: Banner P4 smart vision sensor

alue: 100% inspection ensures high quality.

ote: P4 smart vision sensors include various tools

r many error proofing applications.

he P4 bead tool is created specifically for 100% bead

spection applications.

or bead inspection applications where critical

easurements are not required, the iVu image sensor

rovides an simpler alternative.

ptions: For harsh welding environments where weld

platter is present, a borosilicate glass (BSG)

indow is recommended.

P4 smart vision sensor

- sealed IP68 housing

Body Assembly

Error-Proofing / Quality

Adhesive

BA 0


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bjective: Ensure the presence ofdispensed

aterials: structural adhesive, mastic or sealant with a

ost-effective solution.

egment:

ategory:ype:

olution: Banner P4 smart vision sensor

alue: Consistent automated inspections ensures

gher quality.

ote: In this application, the P4 (non-sealed, IP20)

amera is mounted inside an enclosure and provides

ultiple individual inspections at the beginning, end

nd multiple points in-between, to confirm presence ofe bead.

wo area lights on either side of the camera provide

roper illumination.

4 smart vision sensors include various tools

r many error proofing applications.

ptions: For 100% bead inspections, a bead

ol is available for the P4 series.

he iVuPlus image sensor could be used in this same

pot check application proving simpler / faster set up

maintenanceand with a significant cost savings.

Adhesive Bead

iVu Plus with

remote LCD touch screen

Body Assembly

Error-Proofing / QualityAdhesive

BA 0


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bjective: Verify the presence and position of the

dhesive patch.

egment:

ategory:

ype:

olution: Banner Vision sensors

alue: The adhesive patch helps reduce vehicle NVH

noise vibration harshness).

ote: P3 & P4 series smart vision sensors have

een used in these applications in the past with

xcellent results. These devices can accurately

easure the placement of the patch, which may be

ritical if its positioned near a weld-point.

he metal (image below) has a slight impression to

rovide a visual reference to indicate where the edge

f the patch should be placed in order to avoid being

o close to the weld pointbut proper placement was

ill an issue and during welding, the patch could

ecome ignited. The P3 cameras ensured the correct

acement and eliminated the fire risk.

ptions: For more common presence or general

ositioning / orientation, the iVu image sensor performsqually well and is much simpler to implement &

aintain.

patch metal impression weld point

Adhesive Patch

Body Assembly


Part Presence / Position

BA 0


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bjective: Improve the through-put and accuracy

f error proofing accomplished with manual visual

erification.

he mastic adhesive daubs are applied

utomatically and then manually inspectedr correct placement.

egment:

ategory:

ype:

olution: Banner laser emitters

alue: Laser circles at the intended daub locations

rovides efficient operator guidance. Operation is

ow much faster (30 sec vs. 5 min) and morerecise.

he checking process is now more frequent with

ush button ease - vs. the previous where the

perator needed to handle the sharp parts.

odification is also much simpler - no more

mplates are required.

ote: The old method was to use a reference part

s a template and the operator would manually drawrcles in order to compare.

ptions: Laser emitters are available with different

rojected shapes.

Adhesive Daub

Body Assembly


Adhesive

BA 0


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Robot EOAT Cable Dressing

bjective: Reduce production downtime and costs

ue to cable breakage.

he EOAT (end of arm tooling) contains sensors for

art presence and the clamps each have 2 sensors for

osition sensing, which are plugged into I/O blocks.

he cabling that runs down the robot (dressing) may

e communications (Device Net) or discrete I/O, which

re stressed by the robots movement in highly

rticulated applications and with time, fatigue and may

il.

egment:

ategory:

ype:

olution: Banner DX80 Wireless I/O networks.

alue: Costs and production loss is reduced.

ote: The cable dressing is reduced to just DC power

nd the I/O status is communicated wirelessly.

etrofits benefit with Nodes with standard M12 QDs.

ommunications from Node to Gateway (GW) is via

obust industrial RF and is not affected by the weldingrocess.

ptions: GWs at the weld controller may provide

screte I/O, E-IP or Modbus.

Wireless Node with:

12 - configurable I/O via

6 - M12 QD ports

Body Assembly

Error Proofing / Process

Robot Cells

BA 0


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bjective: Verify part presence on the robot grippers

ith a device that provides a greater sensing than

ductive sensors.

egment:

ategory:ype:

olution: Banner Fixed-Field optical sensors.

alue: The 100mm sensing range (on the 18mm dia

ensor) allows less critical sensor positioning by

roviding a greater distance to the target.

arget material & shape variations are more forgiving

an with inductive sensors.

et-up is quicker, and failures due to being hit as a

esult of being too close are eliminated.

ote: Fixed field sensors provide extremely robust

nd reliable sensing in welding environments.

F sensors have no adjustments, and feature

ackground suppressionthe ability to ignore objects

eyond their cut-off range.

ptions: Different fixed field sensing ranges arevailable up to 2 m.

Body Assembly

Error Proofing / ProcessRobot Cell

Robot EOAT Part Presence

BA 0


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bjective: Inspect body attributes to identify the model

r comparison to the build manifest.

egment:

ategory:

ype:

olution: Banner vision sensors.

alue: Cost effective and robust verification of the

ehicle build by comparing hole patterns and structural

mensions.

he P4 vision sensors are easily supported by the Plant;

utside integrators are not essential.

ote: Multiple vision sensors with ring lights individual enclosures inspect and measure body

haracteristics.

ptions: The sealed P4 version eliminates the need for

nclosures. The iVu image sensor offers powerful sort

apabilities and is configured via a simple LCD touch

creen; no PC required.

Model ID

Body Assembly

Traceability

Model ID

P4 smart vision sensor- IP68 housing

BA 0


10/136


bjective: Implement an improved 2D Data Matrix bar

ode reader for Direct Part Marking with Ethernet

utput.

egment:

ategory:ype:

olution: Banner iVu BCR

alue: Ethernet output provides simple interface with

e host controller.

mproved readability and easy set up; no PC is

equired; all device configuration is performed on the

Vu LCD touch screen.

ote: iVu reads both 1D linear & 2D bar codes.

ptions: Different light source colors are available.

Vu with C-mount lens allow ranges to 2 m.

Body Assembly

TraceabilityBCR / OCR

Bar Code Reade

iVu BCR

BA 0


11/136


Wrong part loaded (no pattern match) = FAILCorrect part loaded (pattern match) = PASS

bjective: Ensure the correct bracket has

een placed in the proper location.

he rear deck has a left and right support bracket, they

re different - correct part & placement needs to be

erified.

egment:

ategory:

ype:

olution: Banner iVu Image sensor

alue: Set up is extremely simple; inspections are

obust.

ote: No PC is required.

Vu easily discerns the pattern of the part for proper

entification.

-Mount lens models allows longer range sensing.

ptions: iVu can provide simple pass/fail signals to

aditional I/O blocks, or connect to Ethernet to provide

dditional model ID / sort criteria.

Part Sort & Verify

iVu Plus with

C-mount lens

Body Assembly


Part Position / Orientation

BA 1


12/136


Body Panel Gap Measuremen

bjective: Provide non-contact measurement

verify the gap is within target tolerances.

egment:

ategory:

ype:

olution:Banner vision sensors.

alue: The P4 smart vision sensor provides a cost-

ffective fixed-mount solution for critical measurement

pplications.

ote: Gap measurements took place at four points:

osterior and anterior on the right and left sides.

his installation used P4 IP20 in-line housing type.

ption: P4 in the robust sealed housing eliminates the

eed for enclosures.

Body Assembly


Part Presence & Position


- IP68 housing


- IP20 in either right-angle or

in-line housing types

BA 1


13/136


bjective: Verify the weld cap surface is within

pecification after redress or change-out.

egment:

ategory:

ype:

olution: Banner fiber optic expert controller with

andard fibers pre-assembled to the fixture block

esigned for weld caps.

alue: The quality of the weld cap redress for both tip

nd crown is verified with expert contrast sensing.

ote: The fixture block is made from hardened SS -

e welding robot can clamp onto the fixture without

reakage.

port for air purge allows blow-off if required.

he fibers used are standard and may be replaced in

e field if required.

ptions: For weld cap profiling inspection, Banner

sion is used.

Push button teach

allows for expert

detection.

This surface flaw is

reliably detected.

R55F

Fiber ControllerFiber Assembly

Weld Cap Inspection

Body Assembly


Welding

BA 1


14/136


bjective: Verify the tailgate is true and conforms

tolerances prior to assembly on the vehicle.

egment:

ategory:

ype:

olution:Two Banner ultrasonic sensors mounted

n the fixture.

alue: Robust measurement error proofing

olution.

he sensors provide position repeatability

egardless if the metal surface is highly reflective

ue to oil, or the surface color has changed due to

hanges from the part supplier.

ote:The S18U series has push-button teach for

mple sensing window set-up.

ptions: Sensor face with either a end or side view.

ifferent sensor sizes and ranges with

screte and/or analog outputs are available.

Wave guide accessories focus the sensing window

r smaller sized targets.

Tailgate Shape Conformity

Body Assembly


Part Position

S18U

BA 1


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bjective: Verify the gasket is properly positioned on

e part prior to the process continuing.

egment:

ategory:

ype:

olution: Banner Adjustable Field sensors

alue: The longer range with adjustable background

uppression allows the sensor to be mounted to the

de and out of the way for both tool and operator

ovement.

ote: Q60 series is available in both LED and laser

ersions which provide different size effective beams

nd range.

ptions: Optional protective covers are available for

arsh environments.

Body Assembly


Part Present / Position

Gasket Presence

Q60 with

AMS protective

racket

BA 1


16/136


bjective: Error proof the presence of the nut. The

ail conditions can be either the wrong sized nut or nut

bsent.

egment:

ategory:ype:

olution: Banner remote head style ultrasonic sensor.

alue: The remote head style ultrasonic provides sub-

m resolution.

ote: The remote controller allows simple push-button

et-up for either 1, 2, 3, or 4mmor any custom size

ensing window.

he remote controller is IP67, may be mounted

rectly on the tool and is I/O block compatible.

ptions: Different remote head types are available;

is installation used the 18 mm diameter metal

readed type.

Nut Detection

Body Assembly

Error-Proofing / QualityPart Presence / Position

Q45UR

BA 1


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Part in Position

bjective: Improve system performance with non-

ontact sensors with a greater sensing range and

rgiving for target variables.

egment:

ategory:ype:

olution: Banner Adjustable Field sensors

alue: The part presence and position is verified

efore the robot removes it from the conveyor.

imple range set up via rotary adjustment .

ote: Parts are manually placed on the up feed

onveyor, fed into the cell and removed by theutomation.

Body Assembly

Error Proofing / ProcessRobot Cell

Q60 AMS protective bracket

BA 1


18/136


Model / Style Indicato

bjective: Provide a lean solution for operator

uidance where parts are manually loaded on the up-

ed conveyor which feed to the automation.

egment:

ategory:ype:

olution: Banner TL50 series tower lights with

ultiple pigtails for I/O block connectivity.

alue: Excellent visual indication and simple I/O block

onnectivity.

ote: The indicator surface has no color until the

egment is energized and lit by colored LEDs.

he normal unlit surface versus the high contrast and

venly illuminated energized colored surfaceprovides

oncise visual communications.

lder style indicators use colored plastic surfaces

hich may appear partially lit if background light is

resent and falsely accentuating its color; its OFF, but

ay appear ON. Older styles were visually inefficient

etween on & off states so tended to be larger

iameter.

ptions: Wrap-around labels on the pigtails to quickly

D for I/O block port selection.

aser etch on the segments to quickly ID the color

ombinations.

Option to the two-pigtail

models: TL50 with 5-pin

QD plus a CSF series Y-

cord

Body Assembly

Operator AssistFlex Manufacturing

BA 1


19/136


Part loaded

EZ-LIGHT

Tool-mountable Indicators

bjective: Improve the indication to the operator

nd reduce wasted cycle time due to parts not being

roperly loaded and the subsequent repeat actions.

egment:

ategory:ype:

olution: Banner EZ-LIGHT series indicators

alue: K50L are highly visible, extremely robust

ED indicators that quickly plug to the existing

ontrol architecture.

heir sealed, IP67 housings can be placed right on

e tool in the natural line-of-sight of the operator.

eyond waste reduction, ergonomics are also

mproved with this quickly implemented cost-saving

olution.

ote: The K50L sensor emulator indicators (proxy

ghts) models provide pass/fail indication and are

onnected to the sensor with a common parallel Y

ord; no other changes to the wiring or control logic

re required; no additional I/O are used.

NP versions work with common I/O blocks andith any common PNP sensor E.G.: inductive

roximity sensors.

ptions: Colors & sizes

K50L Parallel Y cordTool-mountable

EZ-LIGHT sensor emulator

proxy lights

=+

Body Assembly

Error Proofing / ProcessPart Presence / Position

BA 1


20/136


bjective: Improve through-put and lower life-cycle

osts with solid-state ergonomic actuators.

egment:

ategory:

ype:

olution: Banner ergo-actuators.

alue: Sealed IP67 and pluggable devices lower

osts and simplify the process. The robust tool-

ountable design reduces the need for enclosures.

ote: Both optical and capacitive types are proven in

e harsh body shop environments.

ptions: VTB series is a general purpose yoke typectuator with an integral indicator in the base.

TB series is similar as VTB but without the indicator.

TB series is similar as well but is certified for

se in safety THC / anti-tie down applications.

50 & K30 are capacitive actuators that detect a hand

side of a glove, but are not falsely actuated by just a

ove without the hand.

pecial laser etch available.

Ergonomic Cycle Star

50 with specified laser etch

Full-size cover

Body Assembly

Ergonomics

Cycle Start

Legacy box solution

VTB yoke actuator

K50 touch actuatorCompact cover

BA 1


21/136


bjective: Improve life-cycle costs and simplify the

stallation with connectorized self contained devices

nd eliminate the traditional enclosure.

egment:

ategory:ype:

olution: Banner tool-mountable control actuators

nd E-stops, connectorized with QDs.

alue: Basic mounting brackets with connectorized

evices replace the traditional enclosure, eliminating

e required sub-assembly and wiring

rouble-shooting of circuits is greatly simplified.

ote: Self-contained E-Stop devices with QDs are

uicker and easier to trouble-shoot versus each

dividual e-stop screw-type terminal connection within

e enclosure to the older style E-stop.

ptions: Integral indication options: none, 1, 2 or

colors when using I/O blocks, more with other

D types or cables versions.

ariations in: actuator type, sizes plus brackets: with or

ithout space for labels.

Tool-mountable E-Stop & Actuators

SSA E-stop

K50 key switch

K30 push-button

Body Assembly

ErgonomicsE-Stop, Cycle Start & Status Indicators

BA 2


22/136


bjective: Verify the bracket is present and in position.

egment:

ategory:

ype:


alue: The installation includes a remote ergo actuator

r the operator to use when the bracket color changes,

hich may happen from batch to batch.

his remote teach function allows the operator to easily

odify the sensors threshold without needing to wait for

e technician to change the configuration.

ote: The P4 smart vision sensor is in the enclosureeside the area light. Behind the enclosure is a live

deo monitor for a quick viewing of the inspection.

ptions: Today an iVu image sensor would best

esolve this application; easier to set-up and lower cost.

Body Assembly



Bracket Position Verify

iVuPlus with

remote LCD touch screen

- IP67 housing

BA 2


23/136


bjective: Verify the presence and position of the two

ackage trays, each with two nuts.

egment:

ategory:

ype:

olution: Banner vision sensors and vision lighting.

alue: 100% quality inspection. Robust & flexible

on-contact installation.

ote: Two vision sensors in enclosures, each with

ne external IR light source, are mounted above the

ol.

quick comparison of pattern and position confirmsuality.

ptions: The contemporary P4 sealed model is

ated IP68 eliminating the need for an enclosure; Its

ns-protecting window is available in borosilicate

ass which provides the best protection in weld

platter installations.

he iVu image sensor could also resolve this

pplication, simplifying set-up by eliminating the need

r a computer.

Body Assembly



Weld Nut Verify


- IP68 housing

VuPlus with

emote LCD touch screen

P67 housing

BA 2


24/136


bjective: Verify the presence and position of various

arts: horseshoe bracket, nut plate & L bracket.

egment:

ategory:

ype:


alue: A low-cost, simple vision solution that doesnt

equire an integrator.

ote: P4 vision sensors in enclosures, each with a

ngle external light source, are mounted above to

spect nut plate & horseshoe bracket placement.

ther vision sensors are mounted to the side to inspecte L brackets.

ptions: The iVu image sensor is configured without

computer; all set-up is achieved via its LCD

uch screen.

Weld Nuts & Brackets

Body Assembly



iVuPlus with remote LCD

touch screen

- IP67 housing

BA 2


25/136


Nuts, Baffles & Gaskets

bjective: Verify the presence and position of

uts, gaskets & baffles.

egment:

ategory:

ype:


alue: Robust, cost-effective solution.

ote: Seven P4 vision sensors are tied into a network

r monitoring, each are mounted in enclosures, each

ith a dedicated LED area light.

ptions: Either the sealed version of the same P4

sion sensor to eliminate the enclosures, or iVu imageensor to eliminate the enclosures and simplify set-up

y eliminating the computer set-up.

Body Assembly




touch screen

- IP67 housing

BA 2


26/136


Nut in Tray Verify

bjective: Verify the presence and position of the

ackage tray with nut.

egment:

ategory:

ype:

olution: Banner vision sensors and vision lighting.

alue: 100% quality inspection. Robust & flexible

on-contact installation.

ote: P4 vision sensors in enclosure with one external

rea light, are mounted 2m above the tool.

ptions: Today, the P4 sealed model or the iVu

mage sensor would provide increased value and lowerosts.

Body Assembly




touch screen

- IP67 housing

BA 2


27/136


bjective: Verify the presence and positioning of the

inch nut to the part; ensure the nuts threads are

entered with the holes.

egment:

ategory:ype:


alue: Simple yet smart vision sensors intended for

e plant floor. All set-up easily executed by plant

ngineering.

ote: This application used early P3 series devices.

ontemporary models provide improved performance,

asier set-up and lower cost.

ptions: Today, the P4 sealed model or the iVu

mage sensor would provide increased value and lower

osts.

Clinch Nut Position

Body Assembly

Error-Proofing / QualityPart Presence & Position

BA 2


28/136


Body Parts Contents

BP 0

Adhesive Bead iVu BP02

Adhesive Bead iVu BP03

Weld Nut Orientation iVu BP04

Weld Nut Orientation iVu BP05

Part Presence & Position - Nut iVu BP06

Nut Thread Inspection iVu BP07

Double Part Detection iVu BP08

Part Presence - Spacers Adjustable Field BP09


29/136


Pass Fail Fail

iVu

sensor

on Robot

Bead

Nozzle

bjective: Provide a lean bead spot check solution

r adhesive and sealant dispensers.

erify correct single bead presence at multiple

cations through-out the dispense cycle.

nsure correct single bead passesand fail if there is

o bead or dual bead.

egment:

ategory:

ype:

olution: Banner iVu Image sensor.

alue: Ensures the bead is present and in the

tended location with a simple, robust device thatsasy to set up and monitor.

ote: The robot triggers the image sensor to take

snap shot during the dispensing process at a

articular location. The sensor and the robot are

tegrated in a manner to cause a fault in the event of a

efective bead.

he iVu remote display is mounted on the fence for

asy access.

ptions: Applications requiring 100% bead

spections and/or critical width & gap

easurement, consider the P4 series smart

sion sensor.

Body Parts


Adhesive

Adhesive Bead

BP 0


30/136


bjective: Provide a lean bead spot check to ensure

e dispensers for adhesive and sealant are

nctioning properly.

egment:

ategory:ype:

olution: Banner iVu Image sensor.

alue: Ensures the bead is present and in the

tended location with a simple, robust device thats

asy to set up and monitor.

ote: The robot triggers the image sensor to take

snap shot during the dispensing process at a

articular location. The sensor and the robot aretegrated in a manner to cause a fault in the event

f a defective bead.

he iVu remote display provides easy access.

lder check systems monitored volume

splacement, or pressure, or flow which only verify

aterial flow from the nozzlebut do not verify its

een properly placed on the part.

ptions: Applications requiring 100% beadspections and/or critical width & gap

easurement, consider the P4 series smart

sion sensor.

Body Parts

Error-Proofing / QualityAdhesive

Adhesive Bead

iVu Image sensor

BP 0


31/136


bjective: Upgrade the existing error proofing which

nly checked for nut presence but did not verify

rientation of the nut.

revious attempts to address this resulted in moderate

uccess but significantly impeded production.

egment:

ategory:

ype:

olution: Banner iVu image sensor.

alue: Quality and through-put has been improved

ith a simple-to-use robust image sensor.

ote: No PC is required for set-up.

he sensor compares and matches the placement of

ach nut to a predetermined image of a properly

aced nut.

he device inspects the nut twice, once before the

ycle and once after. A fault occurring in the former will

revent the press from cycling. A fault in the later will

revent the welder from transferring to the next stage.

uccessful weld nut inspection is dependant uponpplication parameters; testing a variety of parts and

eviewing other variables is key for a robust solution.

Weld Nut Orientation

Body Parts


Nut / Fastener

iVu Image sensor

BP 0


32/136


bjective: Ensure the weld nuts are in the correct

rientation prior to being placed on the part.

egment:

ategory:

ype:


alue: Robust inspection solution with easy set-up.


roper part is presented and the device is push-button

ught via the LCD touch screen.

uccessful weld nut inspection is dependant uponpplication parameters; testing a variety of parts and

eviewing other variables is key for a robust solution.

Weld Nut Orientation

Body Parts


Nut / Fastener

iVu Image sensor

BP 0


33/136


bjective: Verify the pierce nut has been properly

stened, and the hole has no blockage.

egment:

ategory:

ype:


alue: 100 % inspection has been achieved, ensuring

e customer always receives quality parts.


he pattern match tool allows a simple push-button

ach set-up.

ptions:Additional inspection for thread presence

ay be achieved with the same device.

Part Presence & PositionNu

Body Parts


Nut / Fastener

iVu Image sensor

BP 0


34/136


bjective: Verify every nut has been properly

achined and has the internal threads.

egment:

ategory:

ype:


alue: This cost-effective error-proofing has

iminated significant costs in returned product. when a

ngle bad nut has been delivered to the customer.

ote: When the threads are present, the light is

eflected back to the sensor; when absent, there is no

eflection.

his application was originally resolved with P4

sion; today iVu would be applied.

With iVu, the pattern match tool would allow a simple

ush-button teach set-up on the LCD touch screen.

ptions: Thread detection may also be achieved with

ngle point expert photoelectric sensors.

Body Parts


Nut / Fastener

Nut Thread Inspection

BP 0


35/136


Double PartSingle Part

bjective: Improve the double sheet inspection on

e press line to reduce die crashes.

egment:

ategory:

ype:

olution:Banner iVu image sensor.

alue: Reliably verifies single part only and detects

e presence of two parts.

his non-contact solution is easy to correctly set-up;

her types of part detection require contact with the

art where proper set-up is critical & complex.

ote: Visually, the sensor detects a 100% changehen 2 parts are present .

Vu can contain up to 30 different inspection files to

ontend with different thickness metal parts.

ptions: Models with remote LCD touch screen

nd/or Ethernet communications.

Double Part Detection

Body Parts

Error-Proofing / Process

Double Sheet / Part

BP 0


36/136


bjective: Verify the four spacers are in position.

egment:

ategory:

ype:

olution: Banner optical sensors.

alue: The spacers are critical to the dual-wall

ssembly and also support the weld nuts; 100%

spection has been achieved in this harsh

nvironment.

ote: The tool is crowded at the inspection area and

e sensor needs to ignore items in the background.

he QS18 adjustable field sensors are extremelyobust andas the image shows are capable of

king a beating; after a year of production in this weld

ell, the sides of the sensors are worn down due to

ontact with the part, but still operate to specification.

ptions:Accessory protective covers are now

vailable for harsh environments.

Body Parts


Nut / Fastener

Part PresenceSpacers

QS18

BP 0


37/136


Facility Conten

F 01

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


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Objective: Network various loads such as roof

xhaust ventilation (REV), lighting, dust collectors etc.,

o reduce energy consumption with a solution that

stalls easily and provides a good ROI.

egment:ategory:

ype:

olution: Banner wireless I/O networks.

alue: Loads can be scheduled to turn on & off

utomatically with robust wireless monitoring & control.

nstallation is quick and less expensive than other

etworking solutions.

he loads are controlled (scheduled or event driven)a the host EMS system.

ote:The existing loads may have a start/stop

ushbutton or selector switch for local manual control

f the contactor that switches the load. The Banner

olution adds the networking capability to the local

ontrol to facilitate timely shut down and start up for

reaks, lunch, end of shift and weekends.

he REV Solution includes:

) Node Enclosure: a compact non-metallic enclosurewith Node & antenna, power supply, relays and

erminal strip.

) Gateway Sub-panel with GatewayPro for Ethernet

ommunications plus a IP67 Power supply.

FacilityEnergy Conservation

Cost Savings

Energy ConservationFans

GatewayProNode with

external

terminals

F 02


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Continuous Process Monitoring

bjective: Improve efficiencies and lower costs with

eal time monitoring of plant processes.

egment:

ategory:

ype:


alue: Energy reduction and trending analysis provide

ultiple cost savings with an industrial robust radio

olution.

ote: Temperature, pressure, differentials, levels

tc., are used to identify plant energy losses and

epairable leakage-related degradation factors.

GatewayProNode with

internal

terminals

Facility

Energy Conservation

Process Monitoring

F 03


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Powerhouse Data Collection

bjective: Implement a wireless data collection

etwork between the chart recorders in the

owerhouse and the central host control.

egment:

ategory:ype:


alue:The older monitoring process is in place with

xisting analog sensors connected to the paper chart

ecorders.

he addition of Banner Nodes is a low cost and simple

stallation that provides real-time use of the data.

ollection of the paper charts is now redundant.

ote: Placing a Node at each of the Chart Recorders

nd wirelessly transmitting the analog data to the

ateway located at an access point allows real-time

put of the data.

ptions: The chart recorders can be removed

together and the analog sensors input the Node

rectly.

S Certified Nodes are available.

GatewayProIP67 Node with

internal

terminals

Facility

Energy ConservationProcess Monitoring

F 04


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Pond 1

Pond 2

Master

Pond 3

Rain Water Run-of

bjective: Monitor rain water run-off levels in ponds

nd waterways.

egment:

ategory:

ype:


alue: Low cost solution to comply with EPA and

lean Water Act requirements.

ote: A submersible pressure transducer is placed in

ach pond and is connected to the battery powered

ireless Node on the shore.

this example, the three retention ponds areeparated by up to a mile and several buildings.

his level monitoring application used MultiHop data

adios to transmit level information back to a central

ontrol location.

ptions: Other types of sensor (level, flow etc) could

e used; consideration is given to sensor current draw

nd reporting interval.

Facility

Environmental

Process Monitoring

F 05


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Remote Process Monitoring

bjective: Provide continuous monitoring and control

r the remote Tank Farm.

egment:

ategory:

ype:


alue:Banner nodes can accept a wide range of

ensors and transmit the data between buildings and

cross plants.

anner wireless is highly scalable; changes -or

dditions- to where the information needs to be sent is

asily achieved.

ote: Banner V dc line-powered Nodes can accept

ost types of sensor inputs, either analog or discrete.

ptions: Banner flex-powered Nodes can accept

nergy-managed sensors for unique battery powered

olutions.

Facility


Tank Farm

F 06


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Emergency Station Reporting

bjective: Monitor emergency devices such as eye

ash stations and defibrillators to provide an alarm if

sed.

egment:

ategory:ype:


alue: If the emergency device is used the location

communicated to plant security and the medical

am for a quicker response.

ote: Flow or actuation of the device could be via a

screte signal while temperature monitoring could be

chieved with thermocouple or other sensor.

NSI Z358.9 (2009) for Safety Showers and Eye Wash

tations requires certain compliance issues.

ptions: Battery Powered solutions provide a

ompletely wireless solution.

Facility

Human ResourcesSafety Showers and Eye Wash Stations

F 07


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18mm diameter M-Gage

Flat Pack M-Gage

Vehicle Detection

bjective: Replace the induct loop sensors with

ore robust, easier to install solution.

egment:

ategory:

ype:

olution: Banner M-Gage series magnetic field

ensors .

alue: Operating costs are reduced and the system

more reliable.

ote: M-Gage provides a direct replacement for

ductive loop systems and requires no external

equency box. Its unique design allows quick

stallation within a core hole. For best performance,ount the sensor below-grade, in the center of the

affic lane.

-Gage is not affected by temperature, moisture, dirt

r other environmental parameters.

ptions: M-Gage is available as a wired DC sensor

nd can be surface mounted, or located inside

uminum architectural components. The flat-pack

ousing style is intended to fit within a 1/4" or 6 mm

oad surface) saw cut and buried.

he wireless M-Gage intended to be buried; range is

educed ~ 300 m.

Wireless M-Gage

Facility

Door Controls

Vehicle Position

Wireless

Gateway

Receiver

F 08


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Vehicle Detection

bjective: Improve the door controls with a more

eliable single-sided sensor type.

egment:

ategory:

ype:

olution: Banner R-Gage series radar sensors .

alue: Robust sensor that reliably detects cars, trucks

nd trains in extreme weather conditions.

ote: Radar sensors use Frequency Modulated

ontinuous Wave (FMCW) radar to reliably detect

oving or stationary targets.

nlike Doppler radar, these continuously sweepscross a range of frequencies to determine distance as

ell as motion.

ptions: Variations in models for range and detection

ode plus country-specific approval certificates.

Facility

Door Controls

Vehicle Presence

R-Gage

F 09


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Logistics Conten

L01

aterial Call DX80 Q45 L02

aterial Load/Unload Ultrasonic L03


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Material Cal

jective: Improve the existing Material Call

plication by implementing radio with two-way

mmunications.

gment:

tegory:pe:

lution: Banner DX80 series wireless networks

vide two-way communications. The Q45 Call Button

ludes an integral bi-color LED indicator.

lue: Two-way RF communication provides feed-back

he line-side operator; theyll know their request has

en received and when the delivery vehicle is on its

y.

ere is no initial software to purchase and no on-going

dates to be implemented.

tes: The Q45 Call Buttons are located along the

sembly line and communicate wirelessly with the

80 GatewayPro.

80 GatewayPro with EthernetIP communicates

ectly to the Host production system via an access

nt.

o-way communications allows the host to

pond to the operator:

lor 1 = request for parts message received.

lor 2 = the delivery vehicle is on its way.

tions: Automate the material call with Q45 wireless

nsors which detect & signal low levels.

Q45 Call Button

Logistics

Line-side deliveryPull System

L02


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Material Load / Unload

jective: Verify the proper position of the fork

trucks when they load and unload parts.

gment:

tegory:pe:

lution: Banner ultrasonic sensors.

lue: High repeatability of the switch-point

d robust performance.

te: T30U series has push-button teach for

mple set-up.

ra-sonic sensors are not affected by surface

or variations.

T30U series

Logistics

Line-side deliveryVehicle Position

L03


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General Assembly Contents

GA 0

ole Detection iVu GA02

D BCR / Window iVu GA03

/C Fill Line Monitor DX80 GA04

F Remote Actuator DX80-Q45 & K50L GA05

ope-pull Actuator K50 & Rope-Pull bracket GA06

ndon add-on K50L GA07

art Picks PVL GA08

ne-side Part Picks PVA GA09

ne-side Part Picks PVA GA10

ne-side Part Picks VTB GA11

ne-side Status Indicator TL50 GA12

ne-side Key Switch K50 GA13

ver-travel Indicator TL50 GA14

dicator Retrofit TL50 GA15

ulk Part Picks K50 GA16

ulk Part Picks PVA, VTB GA17

itting Part Picks K50 GA18

itting Part Picks PTL GA19

art Removal LX GA20

ool Nest Sensor / Indicator LX GA21

ehicle Detection QT50U GA22

ehicle Detection Ultrasonic GA23

lass Detection Ultrasonic GA24

lass Inspection Fibers & Q60 GA25

lass Tint Verification Light Intensity Sensor GA26

ehicle Transfer Lift Ultrasonic GA27

ehicle Position Q60 GA28

ehicle Position LT3 GA29

arrier Bearing Temperature T-Gage GA30

GV Communications DX80 GA31

arrier Bearing Temperature T-Gage GA32

GV Communications DX80 GA33

art ID/Laser Q60 GA34

osition Mapping/Lasert L-Gage GA35


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bjective: Identify the presence of the hole to signal

m options.

egment:

ategory:

ype:


alue: The iVu is simple to set-up and maintain; no

C is required.

ote: The lens and light selection determines the FOV

field of view and range.

or ranges up to 2 m, the iVu with c-mount lens is

sed; for closer ranges to 30 cm the micro video lenspes are often used.

ptions: iVu can provide either discrete signals with

O Block connectivity, or communicate via Ethernet

P.

General Assembly


Model ID

Vu with c-mount lens and

-branch I/O block cord

Hole Detection

GA 0


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2D BCR / Window

bjective: Read the Data Matrix 2D bar code on the

ear window before the automation removes the part

om the rack.

egment:

ategory:ype:

olution: Banner iVu BCR sensor.

alue: The iVu BCR reads both 1D linear and 2D bar

odes; no PC is required.

ote: The lens and light selection determines the FOV

field of view and range. For ranges up to 2 m, the

Vu with c-mount lens is used; for closer ranges to 30

m the micro video lens types can be used.

ptions: iVu provide both serial and Ethernet IP

ommunications. iVu is available with integral or

emote LCD touch screen.

General Assembly

TraceabilityModel ID

GA 0


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A/C Fill Line Monitor

bjective: Provide a wireless solution to add a limit

witch to the moving a/c purge & fill equipment that

avels independently to the moving assembly line.

egment:

ategory:ype:

olution: Banner Wireless I/O

alue: The production problem that caused damage

both vehicle and equipment if the hose apparatus

as not removed in time is now eliminated.

ote: Multiple a/c & purge moving stations travel

ong side of the assembly line and are manually

onnected to the vehicle to start the process. Theehicle continues a short distance when another

peration is to manually disconnect it and seal the a/c

ystem. Occasionally the operator doesnt reach it in

me and the fill/purge lines are pulled tight and cause

amage to the vehicle and the equipment.

ow a tension-type limit switch is added which is wired

the Node. If the same condition occurs, the fluid

nes disconnect in a controlled fashion and the host

ontrol is wirelessly communicated which shuts off the

rocess.

General Assembly

Error Proofing / ProcessFluid Flow

GA 0


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bjective: Improve the Andon RF remote actuation

evice.

he current devices are not reliable: poor radio

erformance, short range in plants and the batteries

ave a short life.

egment:

ategory:

ype:

olution: Banner DX80 series wireless devices with

45 Remote Actuator and K50L indicators.

alue: Excellent radio performance; batteries have a

ng life and are quick & easy to change. The Actuator

so has integral Andon indication.

ote: In assembly where the operator cannot easily

ccess the rope-pull or other actuators, the Q45 RF

emote actuator can be placed within easy reach.

he Q45 remote actuator has an LED indicator

at provides additional Andon indication.

ypical operation: when activated, the Gateway signal

sent to the host via pin 4. The host controls the

50L indicator via pin 2.

ther systems may use a GatewayPro with E-IP

ommunications to a host or smart Andon marquee.

ll Banner radios provide two-way communications

ith an integral heart-beat / health function. In the

ase of battery failure, the radio can have the K50

dicator change to an alternate color to indicate the

eed for a battery change.

ptions: Other Andon actuator type include: rope-pull

nd ergo grip.

M12 connection

to standard I/O

blocks

DX80 radio

Gateway

K50L LED indicator

OFFno color

1stcolor:

Andon

2ndcolor:

Battery

DX80Q45 remote RF actuator

Integral pushbutton & LED indicator

General Assembly


Andon

AndonRemote Actuato

GA 0


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bjective: Improve the Andon Rope-Pull actuator and

cal indicator.

egment:

ategory:

ype:

olution: Banner K50 series indicator with integral

dicator on a unique rope-pull bracket.

alue: The K50 light / switch is commonly used in

ther GA applications.

s proven to be a cost-effective reliable device; highly

sible LED indication, self-contained with no moving

arts.

lug & play with the existing I/O block architecture.

ote: Activating the rope-pull causes the bracket

echanism to pivot in front of the non-contact sensor.

ypical operation: when activated, the sensor signal is

ent to the host via pin 4. The host controls the LED

dicator via pin 2.

ptions: Various K50 colors are available.

ther actuator type include: ergo grip style and

emote RF activation.

K50 Indicator

with integral

FF50 sensor

Rope-pull

bracket

General Assembly


Andon

AndonRope-pull Actuato

GA 0


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bjective: Add additional indication to the existing

ndon light / switch to improve visual awareness.

egment:

ategory:

ype:

olution: Banner EZ-LIGHT LED indicators

alue: A simple plug & play solution to improve the

sual indication on the assembly line.

ote: The original positioning of the Andon light /

witch is determined for the best positioning of the

ope-pull so its easy to access.

ut in some cases the light is difficult to see at astancea second indicator can be easily added with

common Y cord and positioned in a better location.

50L with its dome shaped illumination surface is the

referred indicator style.

he existing Andon light / switch may use I/O block

rchitecture with the host signal on pin 2.

ptions: K50L models are available in various

olors.

pecific K50L models with more than the

andard number of LEDs (per color) improve

sibility.

General Assembly


Andon

Andon Add-on

GA 0


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Part Picks

bjective: Provide operator guidance with pick lights

ith sensor feedback to confirm the correct item was

cked.

egment:

ategory:ype:

olution: Banner Pick-to-Light devices: Indicators with

tegral ergonomic sensors.

alue: Improved through-put time and accuracy.

ick Lights simplify the process and helps minimize

aining requirements.

he single-point sensor types provide a lean solution.

ote: Used for both line-side and kitting part picks.

he array types cover a large area in front of

e bin.

he optical FF sensor (100mm range) reliably

etects black or dark colored gloves.

he capacitive Touch sensor reliably detects the hand

ven when thick Kevlar gloves are being worn.

ptions: Indicator size, Number of colors, Internal

gic, Sensor types.

FF100 optical sensor detects dark gloves Touch ergo sensor Touch ergo sensor with thick gloves

General Assembly

Operator Guidance / AssistPick to Light

GA 0


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Line-side Part Picks

bjective: Provide operator guidance with pick lights

ith sensor feedback to confirm the correct item was

cked.

egment:

ategory:ype:




ote: PVA is an opposed style with emitter and

eceiver which provide dual-sided pick light indication.

ptions: PVA is available in four heights.

arious mount options as well as protective covers are

vailable.

General Assembly


GA 0


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bjective: Apply lean mistake proofing array

ensors with pick lights to assist the operator in

electing the correct parts.

egment:

ategory:ype:

olution: Banner Part Pick array devices.

alue: Array devices cover a wide area so the

perator is reliably detected regardless how they reach

and remove the part form the bin.

ick to Light simplifies the process and helps minimize


otes: This installation uses PVA (opposed mode)

eries with heavy-duty protective covers

ecommended for picking larger metal parts that might

rike the array.

ptions: PVD or PVL series operate in either diffuse

r retro reflective mode for single-sided sensing.


General Assembly


GA 1


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bjective: Provide operator guidance for part

election with pick lights and provide a signal to

onfirm the correct item was selected.

egment:

ategory:ype:

olution: Banner VTB series: Indicators with integral

oke / finger-swipe sensor.




otes: VTB devices are robust, sealed IP67 and use

gh quality LEDs.

ptions: Colors, logic & connectivity.

ounting and protective covers.

General Assembly


GA 1


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bjective: Upgrade the indicators to improve visibility

nd simplify the installation.

egment:

ategory:

ype:

olution: Banner customized TL50 series indicators.

alue: Pre-assembled, sealed indicators with

mproved visibility (no colored plastic windows) and

onnectorized for a simple plug & play solution.

ote: When not energized, the surface is plain without

olor; when off, stray ambient light doesnt create

onfusion.

nce energized the colored LED create a high contrast

dication.

ptions: Per customers request: TL50 with dual

gtail QDs, each 2 m in length, I/O block compatible,

nd kitted with brackets.

General Assembly

Operator Guidance / Assist

Visual Management

Line-side Status Indicato

OFF ON

GA 1


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bjective: Improve the key switch to a more compact

wer cost device.

egment:

ategory:

ype:

olution: Banner customized K50 series.

alue: Cost-effective solution in the common K50

rm-factor.

ote: This 3 position key switch model has no

umination, the dome is a solid yellow color.

he 1 m pigtail QD is I/O block compatible.

ptions: Per customers request: Illuminated models,

dditional key movement types.

General Assembly


Pick to Light

Line-side Key Switch

GA 1


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Over-travel Indicato

bjective: Provide a lean solution for the conveyor

ver-travel indicator.

egment:

ategory:

ype:

olution: Custom Banner TL50 series tower lights

ith multiple pigtails for I/O block connectivity.

alue: Dramatic lowering of costs and greatly

mplified installation. Previously, an indicator needed

be mounted on an enclosure for the field

rminations.

ote: The indicator & horn energize if either

echanical limit switch is activated. The Safety I/Oock will provide power only.

ptions: Per the customers request: the first pigtail

D (branch 1) has male connections for the I/O block.

he other two pigtail QDs are both female to connect to

e switches. Model: TL50YAQP-10822

3 Pigtail QD Label

Limit Switch 2 Branch 3 LS2

Limit Switch 1 Branch 2 LS1

Safety I/O Block Branch 1 SI

GA 1

General Assembly


Visual Management


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model

SMBAMSTL50M30

retrofit bracket

bjective: Improve the older indicators with

ontemporary devices that are easier to install,

aintain and improve the visibility.

egment:

ategory:ype:

olution: Banner TL50 retrofit solutions.

alue: Indicators with industry standard M12 QDs, or

ustomized to suit the existing equipment.

ote: Retrofit brackets allow easy drop-in

placement.

ptions: Per customers request: connection details,evated mounting hardware and kitted solutions.

Before After

Indicator Retrofi

GA 1

General Assembly

Operator Guidance / AssistVisual Management


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election with highly visible pick lights and an

rgonomic sensor for system feedback.

egment:

ategory:ype:

olution: Banner K50 series: indicators with integral

ensor.




otes: K50 devices are robust, sealed IP67 and use

gh quality LEDs. The 50 mm dia indicator providesxcellent visibility.

he integral LP optical sensor is aligned on a retro

eflective target up to 2 m distance; the operator

terrupts the beam for actuation.

he integral FF100 optical sensor provides a 100 mm

ensing zone for the operator to wave their hand by.

eing a single-sided sensor, no alignment is required.

ptions: Mounting brackets and protective covers.

Bulk Part Picks

General Assembly


Protective cover

GA 1


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bjective: Provide various solutions for the station:

rray for part picks, ergo actuators plus sensors for

ontainer present and door open.

egment:

ategory:ype:

olution: Banner arrays, ergo actuators and sensors

alue: More sensors = more solutions.

otes: The arrays allow a complete passive

teraction from the operator since they may require

wo hands to pick the larger parts.

he VTB is an ergo actuator to signal when more partsre required.

he sensors verify both fully closed or open door.

Bulk Part Picks

General Assembly

Operator AssistPick to Light

PVA opposed-mode

VTB

GA 1


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election with pick lights and provide a signal to

onfirm the correct item was selected.

egment:

ategory:ype:

olution: Banner Pick Light devices: Indicators with

tegral sensor.




ote: All K50 devices are robust, sealed IP67 and

se high quality LEDs.

ptions: Colors, Connectivity, Mounting.

Kitting Part Picks

General Assembly


GA 1


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Kitting Part Picks

bjective: Provide operator guidance for Kitting part

cks when building more than one kit at a time.

egment:

ategory:

ype:



alue: Lean system flexibility and value can be

creased by combining standard discrete products.

ote: The capacitive touch sensor reliably detects

e hand even when wearing gloves.

kitting applications, the touch sensor provides anesthetic aspect.

perator feedback is improved when the device

rovides an automatic acknowledgement by changing

olor.

ptions: Models, Indicator size, Number of colors,

ternal logic, Sensor types.

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.

tandard discrete products with simply modifications.

ual pigtails and unique laser

ch contributes to a

uccessful lean solution.

General Assembly


Pick to Light

GA 1


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bjective: Verify the part has been removed and

aced in the collection bin.

egment:

ategory:

ype:

olution: Banner LX sensor arrays.

alue: Parts made of any material -metal or plastic-

re detected as they fall through the optical array. The

art to be verified may pass through at high speeds and

ways be reliably detected.

ote: LX series standard models include an integral

utput pulse stretcher with a 5 msec duration - typically

sed with higher speed automated processes. Foreneral assembly applications, the integral output pulse

retcher with a 500 msec is typically used.

-Cords simplify the installation and allow a single

ome run cable to the control system.

ptions: An additional Y cord allows an EZ-Light easy

dicator addition for local feedback that the past has

een detected.

General Assembly


Part Put

Part Remova

GA 2


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bjective: Indicate when the unique tool is required

r the process and verify with feed-back confirming it

as removed from its tool nest.

egment:

ategory:ype:

olution: Banner LX series part presence arrays and

50L series indicators.

alue: Tools may have irregular shapes and

acement in the nest may vary; all types will be

etected with the array sensor and tool positioning isnt

itical.

ote: Select LX series models operate in lightperate to provide a signal when the tool is removed

om the tool nest.

ptions: The K50L indicator can receive its signal on

n 2 and the sensor sends its signal on pin 4 to allow

single I/O block port may be used.

General Assembly

Operator Guidance / AssistFlex Manufacturing

Tool Nest Sensor / Indicato

GA 2


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Pallet detect B

Vehicle detect A

Output A

Vehicle present

Output B

Pallet present

Output B

Pushbutton

Output B

Indicator

Output A

Pushbutton

Output A

Indicator

Sensor Power

Indicator

Target Signal

Strength Indicator

bjective: Improve the Bar Code trigger signal with a

obust sensor solution for the detection of vehicle and/or

allet thats not affected by vehicle color.

egment:

ategory:ype:

olution: Banner ultrasonic sensors

alue: Specific models have 2 independent set points

nd could be used to detect both vehicle and pallet in the

ngle sensor, eliminating the need for a sensing device to

etect the pallet.

ll models have push-button teach and include set-point

window capabilities to increase the flexibility of theevice for a range of application parameters.

ote: Longer range models (to 8 m) are mounted above

e vehicle to detect vehicle roof and/or pallet.

ptions: Different ranges plus analog versions.

Model QT50U

range to 8 m

General Assembly

Traceability/IDPart Presence / Position

GA 2

Vehicle Detection


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bjective: Improve the sensing of the vehicles

ith a more robust solution.

egment:

ategory:

ype:

olution: Banner ultrasonic sensors.

alue: Single-sided sensor that ignores color

fferences and has easy to use, yet precise

ensing window set-up options.

otes: Not impacted by the air movement created

y the large fans that are used seasonally.

ptions: This installation used Banner series45U. Current models have improved

erformance and lower costs.

T30U series

General Assembly

Traceability/ID

Part Presence / Position

GA 2

Vehicle Detection


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Glass Detection

bjective: Improve quality in the glass cell by

eplacing the mechanical-contact switches

ith non-contact sensors.

egment:

ategory:ype:

olution:Banner ultrasonic sensors.

alue: Non-contact highly reliable switching,

egardless of transparency.

ote:Ultrasonic sensors are not affected

y surface color variations.

ush-button teach simplifies the sensingindow set-up procedure.

ptions: This installation used Banner series

45U. Current models have improved

erformance and lower costs.

General Assembly

Error Proofing / ProcessGlass Cell

T30U series

GA 2


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Glass Inspection

bjective: Implement multiple error proofing solutions

the glass cell to resolve: robot part position, verify

resence of the electric connector and verify the

resence of the window tint.

egment:ategory:

ype:

olution:Banner photoelectric sensors.

alue: More sensors, more solutions.

ote: Opposed mode fiber optics detect the windows

dge for robotic part positioning as well as verifying the

resence of the tinted window.

he opposed mode fiber controller R55F

eries is push-button teach for simple set-up.

he LED signal-strength bar graph provides precise

dication for simple set-up and maintenance.

n adjustable field sensor detects the cable.

he adjustable field sensor Q60 series is allowable

ith different light source types to suit the application

arameters.

ptions: Q60 protective cover bracket are available

ecommended when mounted near material handling

acks.

R55F Q60 AMS

General AssemblyError Proofing / Process

Glass Cell

GA 2


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bjective: Verify the presence or absence of tint in

e window for manifest comparison.

egment:

ategory:

ype:

olution:Banner light intensity sensors.

alue: Banners light intensity sensor discerns no

nt, single or double tinted glass and are self

ontained devices with simple push-button set-up.

otes: In the image to the right, the robot places

e glass on a fixture; the sensor is mounted below,

med upward where the basic plant lighting from

bove serves as the light source.

ultiple sensors can be used to generate a positive

gnal when tint is detected, or when no tint is

resent.

ptions: For greater resolution or critical set-up,

odel DF-G1 fiber controller provides a digital

splay and additional configuration options.

o external condition the ambient light, a diffuser

ould be placed in front of the plant lighting toiminate hot spots.

or more challenging light intensity comparisons, a

sion back light provides an extremely even light

ource.

General Assembly

Error Proofing / Quality

Glass Cell

Mini-Beam series LED Back Lighting

GA 2

Glass Tint Verification


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Vehicle Transfer Lif

bjective: Improve the sensor that detects the

osition of the vehicle on the locating pins.

egment:

ategory:

ype:

olution: Banner ultrasonic sensors

alue: Ultrasonic detection allows window type

ensing fields which allows greater flexibility in position

etection.

ush-button teach allows simple set-up.

ote: Ultrasonic sensors are self-contained and I/O

ock compatible.

General Assembly


Vehicle Transfer

S18U

GA 2


77/136


Vehicle Position

bjective: Verifying vehicle positioning on the

onveyor.

egment:

ategory:

ype:

olution: Banner photoelectric sensors.

alue: After the previous transfer, proper position is

erified prior to further inspections.

ote: ModelQ60 adjustable field with background

uppression is available with either laser

r LED light source.

ptions: Brackets for basic installation as well asrackets that also provide mechanical protection are

vailable.

General Assembly


Part Position

Q60 AMS

GA 2


78/136


Vehicle Position

bjective: Monitor the position to the vehicle relative

its location within the assembly footprint to

ccurately communicate torque for traceability.

egment:

ategory:ype:

olution: Banner laser sensors

alue: Model LT3 time-of flight laser is a robust

evice with simple push button set-up.

ote: The LT3 in retro-mode with analog

utput provides a linear output over the length of

s sensing range.

aximum range is 50 m.

ptions: Brackets for basic installation as well as

rackets that also provide mechanical protection are

vailable.

General Assembly

Traceability/IDPart Position

LT3

AMS protective bracket AMS basic bracket

GA 2


79/136


bjective: Reduce downtime due to overheating

earings by providing early warning with non-contact

ensing.

reventative maintenance will periodically verify the

orrect grease level in the bearings but unexpectedown-time due to bearings over-heating and seizing still

ccurs.

egment:

ategory:

ype:

olution: Banner T-Gage temperature sensors.

alue: The T-Gage sensor passively detects the

mperature of the surface from the IR emissions.

ote:Multiple T-Gage sensors are mounted on the

onveyor line positioned to sense the roller bearings as

e carrier passes. As the roller bearing fills the FOV,

e nominal bearing temp is detected.

the bearing grease amount has diminished, the

mperature is much higher, sensor reading spikes and

e output is detected.

-Gage is a self-contained sensor which is I/O blockompatible.

ptions: T-Gage can be connected to a Banner

ireless Node and have its I/O status -either analog or

screte- communicated across the plant.

T-Gage

General Assembly

Error-proofing / process

Conveyance / Drives

Carrier Bearing Temperature

GA 3


80/136


AGV Communications

bjective: Wirelessly communicate the status of the

GV to the remote control system.

onitor devices on the AGC such as switch status or

n the AGV such as on-broad diagnostics to verify

roper operational parameters.

egment:

ategory:

ype:

olution: Banner wireless networks.

alue: Improve the process with 100% quality

spections and continuous monitoring.

wareness to potential issues is immediate; responseme is improved and costs minimized.

otes: Wireless Nodes may communicate I/O status

om common plant devices, either discrete or

nalogue.

ata radios wirelessly transmit & receive serial or

thernet communications.

General Assembly

Error-proofing / process

AGV / AGC

GA 3


81/136

Banner Engineering Corp. 9714 10th Avenue North, Minneapolis, MN 55441 Phone: 1.888.373.6767 www.bannerengineering.comBanner Engineering Corp. 9714 10th Avenue North, Minneapolis, MN 55441 Phone: 1.888.373.6767 www.bannerengineering.com

Connector Cover Plug

jective:Identify the actual build and confirm

he manifest.

rify presence of either: block heater

nnector or cover plug.

lution:Banner photoelectric sensors.

nefit:Cost-effective solution.

te:Q60 series provides accurate switching

eatability with precise background

ppression.

e laser version provides a small concise

ak for small targets.

Part ID / Lase

GA 3


82/136


Position Mapping / Lase

ner Engineering Corp. 9714 10th Avenue North, Minneapolis, MN 55441 Phone: 1.888.373.6767 www.bannerengineering.com

bjective:Confirm the coordinates of the

mpty pallet prior to robot loading parts.

lution: Banner L-Gage

nefit: Cost-effective solutions.

ote:Robot makes an initial sweep of the

mpty pallet for laser gauging, for accurate

acement of finished parts.

OM:Please contact Banner.

GA 3


83/136


Interior Parts & Sub Assemblies Contents

IP 01

Pneumatic Moving Tool DX80 IP02

System Status Indication EZ-LIGHT IP03


84/136


bjective: Incorporate 100% error proofing to the

neumatic tool to provide quality verification.

egment:

ategory:

ype:

olution: Banner wireless I/O.

alue: Equipment parameters ar

Documents

Automotive Application Book April, 2014