In our world of mass production where sophisticated robots perform complex assembly tasks hour after hour it is quite easy to imagine a world, in the not too distance future, where human involvement in the assembly process is confined to the history books. However, whilst science fiction is fast becoming science fact the present day reality in production line assembly is a huge dependency on human ability.
The production of motor vehicles and white goods, for example, requires many repetitive and monotonous assembly tasks to be performed. Lack of concentration on the job in hand, often exacerbated by a noisy environment, leads inevitably to human error and costly re-work.
Leading UK sensor specialists Turck Banner, backed by their American parent company, Banner Engineering, have been helping industry to tackle this problem for a number of years offering pick-to-light sensors in various forms.
Pick-to-light solutions follow the same basic format in that they provide the operator/assembler with a highly visible indication of a specific sequence in an assembly process. The sequence progression can be automatic i.e. the action of removing a part from a particular bin activates the light of the next bin in the sequence or be operator driven after each part is selected.
PVA & PVD Series PARTS VERIFICATION ARRAYS
With Banner’s Parts Verification Array (PVA) to light their way assemblers never need to guess, “What’s next?” Highly visible job lights on each emitter and receiver guide assemblers through the correct part picking sequence, reducing the occurrence of missed parts and parts assembled in the wrong order. PVA is a simple two-part system that does not require an additional controller box, the emitter and receiver interfaces easily with existing process controller.
The PVD Series Parts Verification Sensor features large bright green and red job lights that provide distinct visual prompts to guide assemblers through a part picking sequence and notify of an incorrect or out-of-sequence selection. The PVD is ideal for multi-part pick-to-light assembly, order packing and fulfilment as well as bin picking, part sorting, collating and error proofing applications. Especially significant is the PVD's unique patent-pending one-piece self-contained emitter/receiver design that offers automatic sensing mode selection of either the diffuse or retro-reflective sensing mode depending on the presence or absence of a retro-reflective target material. The diffuse mode is ideal for smaller bins and has a sensing range up to 400 mm while the retro-reflective mode accommodates larger bins with an extended 2 metre sensing range.
The PVD is well suited for a wide range of applications in automotive, cosmetics, printing, mailing, material handling and other labour intensive industries with strict process requirements. Also unique is the PVD sensor's ability to automatically compensate for changing sensing conditions. The patent-pending completely self-contained solid-state microprocessor design continually tests operating conditions and self adjusts to compensate for the degrading of returned signal changes that often occur in industrial environments.
The PVD offers a compact package size at just 30 mm wide by 15 mm deep and is available in two sensing lengths: 100 mm or 225 mm. The PVD is constructed with a robust metal housing and a large selection of heavy-duty metal brackets and protective covers are available for added mounting flexibility and protection in particularly rugged environments such as automotive assembly operations.
The PVD also features 12 to 30V dc operation, DIP switches to select either PNP (sourcing) or NPN (sinking) output which operates either normally open or normally closed, flashing or steady job light, gating polarity control and a 2 metre unterminated cable or a 2 metre cable with 5-pin Euro-style connector.
EZ-LIGHT SMART INDICATOR LIGHTS
These water and oil-tight sealed units have coloured lights, either solid or flashing, that indicate the status of a machine or process. The EZ-LIGHT was developed to replace panel indicators, post and stack lights with a single compact unit that is sealed and IP67 rated. It features a rugged, solid-state design with no bulbs to burn out or replace.
EZ-LIGHT is currently available in three configurations to perform in a variety of applications:
3-colour general purpose (red/yellow/green or custom colours)
Multicolour 7-function featuring enhanced indication capabilities and flashing rates
A style that acts as a large remote indicator for EZ-SCREEN® safety light curtain status
Housing styles include an 18 mm barrel, right-angle 18 mm T-style and right-angle 30 mm T-style that are compatible with the widest range of mounting hardware common to industrial automation applications. With EZ-LIGHT’s compact, unobtrusive size and mounting flexibility, it is easier than ever to install indicator lights and locate them near the equipment operator.
With their compact size, rugged sealed construction, indication flexibility and easy installation, EZ-LIGHT smart indicator lights are ideal for nearly any process or machinery status application. Example applications include the following:
Indicating machine or process status modes including RUN, STOP, RESET, ALERT, READY, WARNING, HIGH, LOW, EMPTY and many more
Indicating PASS and FAIL for part manufacturing or process monitoring
Providing visual illumination for pick-to-light and bin assembly
Providing larger, operator-friendly safety indications on machinery
Rugged and compact EZ-LIGHT models are rated IP67, oil and watertight with Euro-style QD connectors that require no soldering. All models are compatible with PLC or other logic-level control outputs. EZ-LIGHT 3-colour general-purpose models feature red/yellow/green multifunction display as standard with optional custom LED colours. Available in nickel-plated brass 18 mm barrels or thermoplastic 18 and 30 mm T-style right-angle models. 10-30V dc general purpose EZ-LIGHTs are available to receive NPN or PNP inputs depending on the selected model.
VTB OPTICAL TOUCH BUTTON
VTB is a range of ergonomically designed optical touch-buttons with a picking light integrated into the base. VTB buttons mount near bins in a workstation. As the assembler removes each part, he or she touches the corresponding VTB button to signal the controller to switch the job light for the picked bin off, verify that the correct part has been taken and activate the job light of the next bin to pick in the sequence. VTB buttons have no moving parts and are sealed to IP66. The outputs require no physical force and activate when a finger inserted in the “touch area” breaks an infrared beam. The ergonomically designed buttons increase production quality and efficiency, without the hand, wrist and arm stress associated with repeated mechanical switch operation.
K50 COMBINATION SINGLE BEAM SENSOR AND PICKING LIGHT
The K50 is the very latest product in this family with it’s unique design that combines a single beam sensor and a highly visible picking light in one industrial, heavy duty, IP67 rated housing.
A polarised retro-reflective version giving a 2 metre sensing distance and a 100mm diffuse mode version with background suppression are available. K50’s are AS-I field module compatible (40ma@24Vdc)
In order to maintain aesthetically pleasing uniformity on an installation K50’s are also offered in a mechanical push button version.
The K50 range offers quick and easy mechanical and electrical installation with a choice of M12 pigtail connector or cable versions.