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Automotive Applications:
Sealer Inspection,
Adhesive Bead Inspection,
Precision Measurement,
Part Orientation,
Stud Inspection,
Sun-Roof and Moon-Roof Inspection,
Badges,
Emblems,
Decals,
Wheel Inspection,
Beta Patch Inspection,
Fuel Filler Inspection,
Door Handles,
Gaps,
Running Boards,
Lights,
Bumpers,
Body Side Cladding
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- Timing Marks
- Snap Ring Inspection
- Precision Part Measurement
- RTV Bead Inspection
- 2D Code
- Object Character Recognition
- Cylinder Head
- Tensioners
- Connection Rods
- Oil Cap
- Spark Plugs
- Motor Mounts
- Valves
- Gear Teeth
- Piston Heads
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- Fabric Inspection
- Precision Measurement
- Leather Inspection
- Material Tear Inspection
- Button Inspection
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To inspect molded plastic steering wheel components for excess or deficient material
Description:
A high-resolution PresencePLUS P4
OMNI 1.3 mounted above a production line inspects steering wheel components after they are
molded. The P4 OMNI looks for areas with excess material or too little material.
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To make sure that multiple connectors have been inserted into a door panel and are
aligned
Description
After a worker inserts nine connectors into a door panel, the worker places the panel in an
inspection station, where a PresencePLUS P4 OMNI verifies that all connectors are in place
and upright.
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To inspect a temperature sensor inside a duct used in an automotive clean air system
Description
After a vacuum mass-airflow test of an automotive duct, a shuttle moves the PresencePLUS Pro
into position above an open end of the duct. The PresencePLUS Pro verifies that a
temperature sensor is still in place inside the duct and is undamaged.
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To verify that fuses of the specified amperage are in the correct location in a fuse box
Description
A PresencePLUS COLOR Pro vision sensor inspects color-coded fuses in a fuse box to verify
that each fuse is in the correct location.
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To detect the color of automotive interior door handles
Description
A PresencePLUS P4 COLOR OMNI vision sensor detects interior door handles that are the wrong
color for the vehicles being assembled. An on-axis light, attached with specialized brackets, provides even, diffused illumination
to reduce glare.
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Semiconductor & Electronics Applications:
The semiconductor industry, as well as electronics, with their minute and fragile parts and clean rooms,
present special challenges for sensors. A proven integrator is a must.
This application sample demonstrates an inspection of stamped phone contacts (pins). Vision
tools used in this application include a Line Find, Origin, Data Instance, Template with
Blob Analysis, Output, and Pass/Fail tools. A Control Panel program file is included in this
example.
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This in an application example of the inspection of stamped connector pins to ensure that
their size, shape and position on the bandolier are within specification. Vision tools used
in this application includes Origin, Line Gauge and the Template tools.
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To detect when a bonding wire breaks
Description
A pair of fiber optics in opposed mode are located below the bond wire. When the wire breaks
and falls through the beam, an adjustable one-shot output pulse is energized. This application does
not require a consistent positioning of the bonding wire. The dual fiber D12 series has a unique,
ac-coupled amplifier that senses tiny signal changes when the target moves through the beam.
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To monitor the presence or absence of bond wire
Detecting the presence of a bond wire requires a high-powered sensor. The high-powered D12,
used with a plastic fiber optic, has the optical gain necessary to sense a bond wire as
small as 80 microns in diameter.
This application requires the position of the bond wire to remain controlled, with minimum
flutter, in front of the fiber optic sensing tip.
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Using safety light curtains to guard work cells is an effective and efficient alternative to
hard guarding and access doors. When safeguarding in semiconductor wafer processes, special
care and attention must also be considered to address problems associated with electrostatic
discharge (ESD). Applying the right safety components enables safeguarding employees while
protecting equipment and semiconductor product.
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To determine if a polarity-sensitive capacitor is properly oriented
Description
The D11 Expert with a diffuse rectangular array of the fiber optics verifies that a
capacitor inserted in a circuit board is correctly orientated, by detecting the polarity
marks on the side of the capacitor.
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To provide door guarding in an environment cleaned with harsh chemicals, using a fiber optic
interlocking switch
Description
In an environment that is frequently wiped down with harsh cleaning chemicals, a fiber optic
interlocking switch made from 316 stainless steel resists corrosion.
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To verify that all glass hard disks are removed from the holding rack after the disks are
rinsed.
Description
After disks of clear glass are rinsed in a rinsing machine, the U-GAGE T18 ultrasonic sensor
pair in opposed mode reliably senses whether any disks remain in the rack.
Photoelectric clear object detection sensors are not recommended for this application
because of the spray rinse.
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Food & Beverage Applications:
Difficult conditions, varied requirements, challenging applications. USS can help
boost efficiency and reduce costs whatever your environment: wet rooms, clean rooms, cool rooms,
acidic and alkaline detergents.
- Food Inspection
- Label Inspection
- Can Inspection
- Bottling Inspection
- Liquid Fill Inspection
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To make sure that a fill tube has not broken off and fallen into a bottle in a beverage
packaging operation
Description
During bottle filling, there's a risk that the fill tube can come loose and fall into a
bottle, causing the liquid to squirt onto the line rather than filling subsequent bottles. A
PresencePLUS P4 EDGE vision sensor can detect the tube in a bottle, signalling the line to
shut down so the problem can be corrected.
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To inspect boxes of candy to make sure that it contains the correct chocolates, based on
color.
Description
A PresencePLUS P4 COLOR OMNI mounted about a conveyor inspects each box of 12 chocolates,
making sure each paper nest contains the correct type of candy, based on color. It rejects
boxes that have the wrong chocolate in a nest, are missing product or have damaged product.
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To ensure that when bottles are placed on the conveyor, there is not a downed or stuck
bottle in the placement area. This prevents damage to the bottle handling equipment, as well
as potential jams further down the conveyor
Banner’s Clear Plastic EZ-ARRAY is designed to monitor an area of the conveyor that single
point sensors cannot. With its polarized technology, discrete outputs can be used as an
alarm to notify the bottle handling equipment controls that there is an obstruction on the
conveyor.
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To verify the presence of a date/lot code imprinted on a clear bottle filled with a clear
beverage
Description
A PresencePLUS OMNI inspects the neck of a clear plastic bottle to verify that the date/lot
code has been imprinted on the bottle. It also confirms that the cap is properly applied and
that the bottle's fill level is within the acceptable range.
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To position all bottles in the same orientation for label application
Description
To detect botles that are not positioned for labeling, an R55 Expert checks for an
inconspicuous color mark on the back seam of foil top wrap.
The R55 Expert color mark sensor reliably detects very small color marks and slight color
contrasts.
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In bottle filling applications, long assembly lines carrying bottles at high speeds are used
to efficiently move the bottles through the various stages of the filling process. A tipped
bottle could cause a jam on the line, leading to costly work stoppages. A solution is needed
that will clearly communicate to maintenance workers where a bottle has tipped.
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Many food and beverage operations require a date/lot code to be present on the packaging.
There needs to be a cost-effective way to verify that the code is present.
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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Medical & Pharmaceutical Applications:
As regulation of pharmaceutical and medical manufacturing grows, sensors become critical for compliance,
and having a proven integrator like USS is becoming paramount.
- Needle Inspection
- Precision
- Measurement
- label Inspection
- Tracebility
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Tamper-evident bands using ultraviolet (UV) luminescent material are used to ensure product safety
integrity on many pharmaceutical products, such as drug bottles and eye drop containers. It is
important to evaluate the position of the tamper-evident band as well as ensure the presence of the
band; it should be positioned around both the cap and the neck of a bottle. A misaligned seal positioned too high, or completely missing would be considered unacceptable and
the product container should be rejected.
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Feeder bowls are effective in parts orientation to begin the automation assembly process. Keeping
the feeder bowl stocked with parts is necessary to ensure the process continues without
interruption. Standard diffuse-mode sensors may have difficulty distinguishing between the bowl and
the presence or absence of parts. Photoelectric sensors with key performance capabilities are
capable of reliably solving these once-difficult applications
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In the pharmaceutical industry, as soon as each vial is filled, a stopper must be properly inserted into the vial.
Description
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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Pharmaceutical box inserts need to be verified and identified before sealing the package in order to
ensure accurate documentation is delivered to the customer. In order to quickly and efficiently
perform this inspection, the data matrix code on the documentation is verified prior to the
final packaging process. USS mounts an iVu BCR sensor 8-12 inches above a conveyor of boxed pill bottles containing a medical
information insert. The iVu BCR reads a data matrix code on the insert to verify it matches the
product on the packaging line.
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To verify that all blisters in a pack have been filled with the correct, undamaged tablets and that
the blisters contain no debris
Description
Tightened federal regulations make the quality of pharmaceutical packaging increasingly critical. A
PresencePLUS Pro COLOR vision sensor inspects blister packs to make sure each blister contains the
correct tablet and that the tablet is not broken. It also detects empty blisters and those
containing foreign matter.
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As glass bottles pass on a high-speed conveyor, a PresencePLUS P4 COLOR OMNI confirms that each
bottle is completely filled and makes sure that the stopper is fully inserted and is the correct
color.
The dual area lights create the optimum contrast for the inspection.
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Clear plastic is used to cover cases of pill bottles before they are shipped. To ensure consistent
packaging and prevent conveyor jams, the plastic film must travel through the rollers at the same
speed as the conveyor transporting the bottles. A sensing solution is required that will communicate
to the rollers to speed up or slow down as needed.
The detection of clear plastic is always a challenge. The optical beam of traditional photoelectric
sensors will burn through clear material, making sensing results unreliable.
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Farm & Agricultural Applications:
Controlling the temperature in a livestock facility ensures minimum loss of life during an equipment
failure.
Description
A flow meter attached to a FlexPower Node monitors the flow of air from a ventilation system. If the
flow stops for longer than a user-defined period, an alarm is sent by email, enabling the staff to
take action before the loss of livestock.
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Temperature monitoring in a livestock facility ensures optimum conditions or minimizes the loss of
life during an equipment failure or weather changes.
Description
SureCross Wireless FlexPower Nodes equipped with a thermocouple or RTD can be easily implemented for
monitoring barn temperature range or dairy bulk tank temperatures, triggering an alarm when the
acceptable temperature range is exceeded.
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With a SureCross wireless network, center pivot irrigation system motors can be monitored without
compromising any existing equipment.
Description
Center arm pivot irrigation systems are used throughout the Midwest to minimize water use and ensure
crop health. Because the sections of the center pivot assembly have to move at different speeds, the
motors moving each section must be monitored to verify each section is moving at the proper speed
and time.
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To monitor level of material in a truck
Description
A U-GAGE Q45U long-range analog ultrasonic sensor monitors the level of materials inside a filling
or holding tank. The Q45U’s microprocessor-based filtering smooths the response to irregularly
shaped objects.
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In a frozen food packaging operation, frozen food in plastic tubs and wrapping need to be inserted
into individual boxes. Occasionally, an incorrect box finds its way into a stack of boxes, or a box
is upside-down. Manufacturers need a cost-effective way to verify that all the boxes are correct
based on the food being packaged on the line.
Description
To verify each box is correct, an iVu Series sensor is configured for a Match inspection with 360
degree rotation enabled.
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To ensure optimum performance and plant growth, temperature and humidity levels must be maintained.
A SureCross FlexPower™ Node with internal battery directly connected to a temperature and humidity
sensor can provide these measurements without costly conduit or cabling, eliminating the need to
manually collect data from multiple sensor locations. IP67 electronics and a variety of filter
options make this product suited for the wide temperature and humidity ranges in a
greenhouse.
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For optimum workflow and loading dock traffic management, it is essential for dock workers to
immediately know of arrivals. M-GAGE Wireless Sensor Nodes mounted on each loading bay signal the
arrival of vehicles by illuminating remotely mounted Banner EZ-LIGHT indicators mounted throughout
the facility. Supervisors can also be alerted to arrivals using their PC or PDA. Workers assemble
quicker at the appropriate dock, and cargo security and facility access are greatly enhanced.
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To ensure efficient and effective composting, the temperatures of the windrows must be measured and
logged constantly. With accurate temperature measurements, you can determine the optimum time to
turn the windrows for quicker compost production.
Composting is the aerobic decomposition of biodegradable organic matter to produce compost, a
nutrient-rich mulch of organic soil produced using food, wood, manure, and/or other organic
material.
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Material Handling Applications:
To detect when a truck backs up to a dock, triggering a light inside the warehouse that signals the
truck's arrival
Description
The M-GAGE S18M is a magnetoresistive sensor that responds to the shift in the surrounding magnetic
field when a truck approaches. The M-GAGE is set up to trigger a signal that activates a light
inside the warehouse, indicating the truck's presence.
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In large factory operations, it is common for AC power to be used as the primary power source for
all conveyors and machines. It can be costly and inconvenient if a separate DC power supply is
needed to power the sensors used to monitor the wide variety of processes taking place on the
factory floor.
In this application, a durable, versatile sensor is needed to detect corrugated cardboard stacks as
they pass on an AC powered conveyor.
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To detect the presence of luggage on an airline conveyor
WORLD-BEAM QS18 Universal Voltage sensors mounted along an airline conveyor detect the presence and
position of passing luggage. QS18 Universal Voltage sensors can be connected to either AC or DC
power, allowing them to operate in large conveyor applications already using AC power without
requiring a separate power supply. The robust, compact housing and multiple mounting options add to
the versatility of WORLD-BEAM QS18 Universal Voltage sensors.
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When packages of various shapes and sizes move down a conveyor belt, it is imperative that they
continue to move so as not to create potential delays or damage due to a jam.
Description
In the event of packages or totes coming around the corner of a conveyor getting caught, a
WORLD-BEAM QS18 Universal Voltage sensor positioned at a bend will communicate to an alarm or PLC
that an object has become lodged in front of it, alerting employees to the presence of a jam.
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To guide a book packer to the next item on the order and to confirm the pick
In a book-packing warehouse, the rack above each carton of books is equipped with a one-piece
EZ-LIGHT PVD pick-to-light sensor. A worker fills orders by selecting the quantity of each book
specified on the packing slip. To help the worker find the cartons from which to
pick books, the PVDs above those cartons are illuminated. The PVD detects the workers hand in the
carton to verify that the title was picked.
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To sense boxes anywhere across the width of a roller conveyor, when sensing is only possible from
under the conveyor
Description
The optics of the S18 fixed-field sensor are ideal for sensing from below a conveyor. Excess gain is
very high at the optimum sensing distance of about 25 mm, but is low at the lens. As a result,
moderate amounts of dirt and dust falling on the lens don't affect sensor performance.
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To accurately measure the height of parcels passing on a conveyor
Description
When triggered by an opposed mode pair of sensors, an array of L-GAGE LT3 sensors accurately
determines the height of boxes passing on a conveyor below the array. The array measures individual
boxes as well as the first box in a tote carrying several boxes.
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To measure height, length and width of boxes for storage and to collect cubing information for
shipping
Description
Cartons moving on a conveyor pass between three pairs of EZ-ARRAY measuring light curtains. The
total number of beams blocked for each pair indicates the size, which is sent to a sorter as an
analog signal. A PLC then diverts each carton to the appropriate storage location.
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To count bolts dispensed from a feeder bowl
Description
The D10A Discrete sensor counts bolts as they drop from a vibrating feeder bowl and pass the sensor.
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Assembly & Manufacturing Applications:
The number of products and applications USS Vision integrates for manufacturing and assembly is nearly endless.
Here, an automated guide vehicle (AGV) delivers assembly line parts to a workstation when the parts are
needed.
Description
Remote, self-contained push buttons attached to SureCross Wireless Nodes can be placed at assembly
line workstations to signal a Wireless Gateway-equipped AGV for replenishment of assembly parts.
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The objective is to maximize operator access to the inspection station while safeguarding the
operator from danger. The importance of area guarding for this application is to detect intrusion
and provide a stop signal, and to provide continual sensing in the inspection station. Here, the
robot picks up material and places it in a package as it moves along the conveyor, and the operator
uses the inspection station to ensure the package was filled with the proper amount and type of
material. This individual must not enter the Protective Field (red area).
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To indicate the bin from which the worker should select parts
Description
Each bin is equipped with an indicator light to guide the worker to the bin from which to pick. The
sensors are part of a wireless network—multiple EZ-LIGHT indicator lights connect to a single
wireless Node, and in turn multiple Nodes connect to a wireless Gateway in a central location, so
personnel can monitor parts consumption throughout the site.
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In flexible manufacturing environments, where operators assemble components with parts supplied by
parts bins, a simple indicator is illuminated to alert stocking personnel to refill the bins before
parts are depleted. Keeping bins stocked with parts without the need of the operator to leave the
station to retrieve and refill improves productivity.
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To verify that only correct parts are on a conveyor, before they are packaged
Description
As fasteners are ejected onto a conveyor, a D10 sensor triggers a PresencePLUS P4 GEO to detect the
presence of correct fasteners in any orientation (full 360 degree range) and to reject incorrect
fasteners.
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USS integrated this application to count bolts dispensed from a feeder bowl
Description
The D10A Discrete sensor counts bolts as they drop from a vibrating feeder bowl and pass the sensor.
Read More
To accurately verify the position of tubing, before the die is lowered
Description
To prevent damage to a die, an L-GAGE LT3 sensor verifies that a robot correctly places a preformed
section of tubing into the lower die of a hydro-forming press. The L-GAGE LT3 sensor measures the
distance to a critical portion of the tubing. The LT3's range allows it to be placed clear of the
die; traditional sensors with their smaller ranges could not be located far enough away.
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To stop a machine’s operation in an emergency, using a module with four output switching channels
Description
The safety module monitors the emergency stop button for actuation, failure modes and
rearming/resetting. It also provides four safe switching outputs and monitoring of device under
control.
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Packaging Applications:
A variety of sensors USS integrates enhance product quality on high-speed packaging lines.
Here, to confirm that each unit includes a product information insert, a Banner 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. If the insert is missing or upside-down, the sensor sends a fail output to the line, and the
package is rejected.
Read More
Feeder bowls are effective in parts orientation to begin the automation assembly process. Keeping
the feeder bowl stocked with parts is necessary to ensure the process continues without
interruption. Standard diffuse-mode sensors may have difficulty distinguishing between the bowl and
the presence or absence of parts. Photoelectric sensors with key performance capabilities are
capable of reliably solving these once-difficult applications.
Read More
To verify the presence of colored caps on plastic bottles
Description
As plastic bottles pass below the WORLD-BEAM Q12 sensor, the fixed-field beam identifies bottles
without caps and rejects them from the line.
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To make sure that a fill tube has not broken off and fallen into a bottle in a beverage packaging
operation
Description
During bottle filling, there's a risk that the fill tube can come loose and fall into a bottle,
causing the liquid to squirt onto the line rather than filling subsequent bottles. A PresencePLUS P4
EDGE vision sensor can detect the tube in a bottle, signalling the line to shut down so the problem
can be corrected.
Read More
To verify the presence and correct color of pour spouts
Description
A PresencePLUS P4 COLOR OMNI vision sensor inspects pour spouts that have been inserted into
detergent bottles. The sensors verify that the spout is present and inserted fully, and that spout
color matches the bottle color.
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To ensure that a dry food package is not underfilled or overfilled
Description
In a food processing line that fills by level instead of weight, an infrared analog L-GAGE Q50
sensor monitors the level of the dry cereal's irregular surface.
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To verify that a date and lot code is correctly printed on film packages
Description
As boxes of film pass the PresencePLUS P4 GEO at a rate of 1000 boxes a minute, the P4 GEO verifies
printed date and lot code. The operator uses the remote TEACH function to set new codes each day,
without using a PC.
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To identify food packages missing hot sealing glue, before the flaps are closed
Description
After frozen waffles are inserted into boxes on a packaging line, hot glue is applied to the flaps.
The T-GAGE M18T sensor detects boxes that are lacking glue, which would not seal when the flaps are
closed.
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Other Applications:
To indicate to the customer which stage of an automatic car wash is in progress
Description
EZ-LIGHT K50L indicator lights glow yellow to indicate a finished phase and green to indicate the
current phase. For upcoming phases, the indicator lights do not illuminate.
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To monitor the level of soap in a reservoir in a car wash
Description
The WORLD-BEAM QS18U ultrasonic sensor monitors the level of soap in a tank in a car wash. The
sensor is mounted atop the reservoir, aiming through the transparent top. The sound waves bounce off
the surface of the liquid.
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To detect a vehicle as it approaches the door of a car wash
Description
A wireless M-GAGE sensor embedded in the ground powers up the car wash and triggers the entry door
when it detects an approaching vehicle. When no vehicle is present, the payment system and the car
wash remain in standby mode, consuming less power.
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To detect when a car or truck enters or leaves a self-serve car wash
Description
The M-GAGE is activated when the customer deposits payment in the pay box. The sensor detects the
presence of the stopped vehicle as the patron washes it. When the vehicle beings to leave, the
M-GAGE detects the shift in wash bay's magnetic field and signals the timer to reset.
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Crane-to-Crane Communication
When multiple cranes are moving in tight spaces, it's imperative to keep them separated to avoid
collisions.
Description
Wireless solutions allow for easy transmission of distance data between cranes so multiple cranes
can service the same area.
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To map the presence of wafers in a cassette
Description
The fibers of the D10 Expert sensor move along the stack of wafers in the cassette, mapping which
slots are occupied and which are empty. The bargraph displays the sensor's status.
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A variety of semi-automated operations which involve the manual feeding and/or removal of parts
exist within the automotive manufacturing process. In many cases such as this robotic weld cell,
operators must be protected from hazards that are created by the automation such as pinch points
from clamps and feed table movement. The solution requires a safeguarding method which can detect
the presence of a hand reaching into the station as well as protect from a cycle start if personnel
are inside the cell.
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It's important that the correct number of chocolates are present in every
box in order to meet quality inspections. You can use a traditional
vision system or traditional photoelectrics. Here, USS places Banner
sensors, positioning them above a conveyor inspecting each passing box for missing chocolates. When
a passing box breaks the trigger beam created by a pair of Q12 opposed-mode sensors, an array of
QS18AF sensors mounted above the box inspect each location for missing chocolates.
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To verify that cans contain the correct amount of ground coffee
Description
The MINI-BEAM sensor pair in opposed mode triggers the fixed-field S18 barrel sensor to sense
the level of ground coffee, which has very low reflectivity.
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- Part's Depot
- Precision Part Measurement
- Robotic Vision
- Traceability
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