Defects and errors in parts and components can negatively impact downstream processes, production efficiency, and product quality. Consistent, reliable inspection of parts and components can help manufacturers identify potential issues early on in the manufacturing process, minimizing lost product and production time. Banner’s expertise in a range of sensing technologies allows us to offer optimal solutions for detecting defects, measuring components, monitoring tolerances, and verifying attributes.
A VE Series Smart Camera, configured to use the bead tool, inspects each door panel for the presence and consistency of adhesive. The camera has a wide field of view and a 2 MP imager capable of detecting even slight inconsistencies in the amount of adhesive applied.
Banner’s Q4X problem-solving triangulation-based laser sensor has no difficulty detecting dark targets on dark backgrounds when there is a height difference. The Q4X provides a reliable sensing solution with best in class excess gain and makes pass/fail judgments based on distance rather than color or reflectivity.
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.
Fiber optic systems are typically used in harsh conditions, including high vibration, extreme heat, and noisy, wet, corrosive or explosive environments. Fibers are also used in confined areas since many models can be bent to fit precisely where needed.
Glass fibers are mostly used in challenging environments, such as applications with high temperatures, corrosive materials or moisture. Plastic fibers are typically used for more general purpose applications where they can tolerate extreme bending and be cut to length to fit in limited space setups.
A large scale pharmaceutical company packages many of their tablet medications into blister packs. Empty trays are fed into an automated distribution machine which dispenses the pills into available cavities. Before being sealed, each tray must be inspected to verify that tablets have been correctly placed, each cavity filled and that there are no chipped or broken tablets.
The Banner Q3X laser diffuse sensor with 100 mm background suppression is ideal for applications that require orientation detection. It offers fixed background suppression which means that the sensor can be set to recognize a specific distance and ignore anything past the set point. The Q3X is set up to detect when the top of a cap is facing toward the sensor and ignore the cap when it is facing away. When it detects a cap facing toward the sensor, a fail output is sent and the cap is rejected and recycled back into the cap sorter.
The Q3X is Banner’s rugged, versatile laser contrast sensor, ideal for applications that require fast detection. As parts go down the conveyor, the Q3X will be able to detect if the o-ring is present based on the taught contrast differences. If the o-ring is not present, the Q3X will see a bright signal level and send an output to the PLC. This alerts operators to fix the error or move the part off of the production line. If the o-ring is present, it will see a dark signal level, and no output is sent.
Conventional sensors can often have difficulty detecting the presence of threads. The WORLD-BEAM QS30’s narrow laser beam can detect whether a hole in the manifold is threaded from a distance of up to 800 mm.
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.
One global provider of healthcare products had been using vision machines to detect particulates in their liquid pharmaceuticals. When the machines were no longer able to detect contaminants to the required percentage level, the company began using human visual inspections. Since many of the particulates are extremely minute, the company needed to install bright and highly uniform illumination in their work stations so operators could effectively verify the quality of products.
A VE Series Smart Camera inspects the product logo on each box before the tube of toothpaste is inserted. As a box enters the inspection area, it is detected by a sensor on the line and an output is sent to the trigger input on the camera, which captures an image of the region of interest (ROI). A red LED ring light powered by the camera enhances the contrast between the product logo and the surrounding packaging.
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.
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.
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.
Banner Engineering’s DF-G1 Series amplifier provides a simple setup and calibration for small part counting applications. Once the amplifier is setup, the easy-to-read digital dual display allows for simple operation because it shows the signal level and threshold simultaneously.
In pharmaceutical packaging, each pocket of a blister pack must contain a tablet, and each tablet must be the correct color. However, it can be challenging for traditional color sensors to reliably see through the reflective plastic of the blister pack. Keep reading to learn how the QCM50 color sensor solves this application.
An SLM Series slot sensor used in combination with an iVu Series vision sensor can be used to detect bottles passing on the line and to verify the presence of a date/lot code. During the labeling process the SLM slot sensor detects each bottle as it passes.