Automated Quality Control

Automated Quality Control

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.

  1. Detecting a Line of Adhesive on a Vehicle Door Panel
  2. 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.
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  1. Detecting Black Parts on Black Door Panel
  2. 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.
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  1. Identifying Presence and Height of a Bottle Cap
  2. The iVu Plus Gen 2 vision system, paired with a Q4X and LEDRB backlight, offer a solution that will provide dependable results.
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  1. Blister Pack Inspection
  2. To verify each blister in the pack, use an iVu Series sensor configured for an Area inspection. The sensor inspects each blister pack to make sure that each blister contains an unbroken tablet.
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  1. Multiple Point Inspection on Stamped Metal Parts
  2. To verify the expected number of holes exists on a small metal part, the iVu Plus TG Image Sensor with Multipoint Inspections can be configured for multiple regions of interest (ROIs) to ensure holes exist and were punched in the correct place. When set up for area inspection, the iVu will scan multiple points on the stamped part to verify the presence or absence of a feature or features of interest.
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  1. Inspecting Blister Packs for Tablet Placement, Position and Shape
    • Inspect blister packs on conveyor
    • Check for defects or missing tablets
    • Rapid product changeovers
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  1. Detection of Cap Orientation
  2. The Banner Q3X laser diffuse sensor is ideal for applications that require orientation detection with small contrast differences.
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  1. Black O-Ring Detection
  2. 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.
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  1. Thread Hole Detection
  2. 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.
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  1. Punch Hole Inspection
  2. To verify that the expected number of holes exist on a small metal part that is not rigidly fixed, use an iVu Series sensor configured for an Area with Motion application. When holes are punched, the sensor evaluates all the holes to make sure that they are present and correctly sized. If any are not, the sensor sends a fail output to the line where the part is rejected.
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  1. LED Lights Used To Inspect Liquid Pharmaceuticals [Success Story]
  2. 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.
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  1. Verifying Product Logo on Paperboard Packaging
  2. 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.
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  1. Date/Lot Code Inspection
  2. 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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  1. Food Packaging Label Inspection
  2. To verify each box is correct, an iVu Series sensor is configured for a Match inspection with 360 degree rotation enabled. An image of the correct box is captured and when the inspection is running, if the sensor detects an incorrect box, the sensor sends a fail output to the line, and the product is rejected.
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  1. Drilled Holes Inspection
  2. This application uses an iVu Series sensor configured for an Area inspection. When holes are punched, the sensor evaluates all the holes to make sure that they are present and correctly sized. If any are not, the sensor sends a fail output to the line where the part is rejected.
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