Detecting Shiny, Reflective Wheel Parts

The reflective and curved surfaces of wheels and hubcaps can pose difficulties for optical sensors, because light is reflected away from the sensors’ receivers. However, Banner's T30R series provides reliable detection using radar.

Application

In an automobile assembly plant, new wheels need to be identified by a side-mounted sensor to be picked up off of a conveyor by robot arms.

Challenge

Several types of automotive parts, including metal components with glossy, reflective, or matte black surfaces, or mirrors and windows, can reflect or absorb the light-based beams of photoelectric (PE) or laser sensors, leading to inaccurate or inconsistent detection results.

Solution

Radar sensors, such as the ones that comprise Banner’s T30R series, provide an alternative to optical detection. With radar, targets can be identified easily independent of color, shape, or reflectivity. The T30R’s variety of outputs and simple programming interface make it a perfect choice for applications requiring advanced detection. When vehicle assembly plants or factories creating auto parts incorporate this technology, they are able to eliminate several common sensor detection issues, halt automated assembly lines less frequently, thereby reducing downtime and increasing production quantities.

Key Benefits

Resolves the issues that challenge laser sensors

One automotive company that switched to the T30R reports that it shows significant improvement over their laser sensors for presence/absence detection of chrome and black hubcaps. Furthermore, the manufacturing team appreciates Banner’s informative software for setting up and fine-tuning the sensor.

Resolves the issues that challenge retroreflective sensors

Another automotive manufacturer reports that switching from photoelectric sensors to the T30R improved their detection of glass car windows on a roller conveyer. The light would pass through the clear glass, so that it recognized the rollers instead of the intended targets. Because the T30R uses radio waves signals instead of light, it provides the company a much more accurate and consistent pattern of response, with no detection misses at a distance of 2 meters. The company also reports success in using the T30R for detecting front and rear bumpers, which have curved shapes, as well as many color variations and often glossy surfaces.

Resolves the issues that challenge ultrasonic sensors

A third manufacturer had been using ultrasonic sensors for detecting rearview mirrors. While the results were accurate with that method, the produced objects are fairly small, and this required constant readjustment of the sensor mounting. When the team installed a T30R radar sensor, they found that mounting it 18 inches away from the items provided flawless detection performance, with no need to stop machinery for realignment of the sensor mount. The company also values the T30R and its software for properly recognizing the difference between the glass mirrors and background surfaces.

Senses a variety of targets without the need to change settings

The T30R series is designed to be versatile. Even if the characteristics of objects vary in terms of their position, shape, color, material, or surface reflectivity, there is no need to stop and readjust the sensor’s detection parameters. The sensor can detect the presence or absence of shiny metal parts or matte black items, or almost anything in between.

Improves production efficiency

Time is money, and downtime is lost revenue. Competitive manufacturers cannot afford to be held back by inconsistent sensor response or missed readings that could cause production-line stoppages. With a T30R sensor, detection is not limited to what can be seen with a targeted and reflected beam of light or ultrasonic waves. If there is an object in the path of a radar beam, the sensor will find it, and production can go full steam ahead.

Featured Product

T30R Radar Sensor for Detecting the Widest Range of Objects

The T30R sensor is a longer-range alternative to ultrasonic sensors, and provides more reliable detection and position feedback in extreme outdoor conditions and other challenging environments. It features a shorter dead zone, better accuracy, and the ability to see a wider range of targets than traditional 24GHz radar sensors.

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