Manuals+

Automotive Rework Bay Solutions

Enhancing Efficiency with Vehicle Detection and Status Indication

Overview

An image shows a stack of colored lights (tower light) above a vehicle in a rework bay, indicating status.

Vehicle Detection

Overhead Detection

Challenge: Inconsistent monitoring of rework bays leads to overfill, increased cycle times, bottlenecks, disrupted planning, and delayed shipments.

Solution:

  • The T30R Radar Sensor, mounted overhead, reliably detects vehicle presence upon bay occupation, preventing unnoticed arrivals and rework delays.
  • Configured in retroreflective mode, it monitors a defined sensing area on the bay floor. The sensor switches output when a vehicle blocks the return signal, triggering a connected TL50 Tower Light to indicate bay occupancy.

Product Visual: Diagram showing a T30R Radar Sensor mounted overhead and a TL50 Tower Light indicating bay status.

Dual Bay Monitoring

Challenge: Monitoring individual rework bays is effective, but monitoring two adjacent bays with a single sensor simplifies inventory and reduces complexity.

Solution:

  • A single Q90R2 Radar Sensor uses two independent detection zones to monitor adjacent rework bays, detecting vehicles of any size, shape, color, or finish, thereby reducing the need for dedicated sensors and inventory.
  • Banner Measurement Sensor Software facilitates quick setup and allows adjustments for tailoring detection zones to specific bay configurations and evolving needs.

Product Visual: Diagram illustrating a Q90R2 Radar Sensor monitoring two adjacent bays, paired with a WLS27 Pro LED Strip Light.

Under-Vehicle Installation

Challenge: Installation constraints, such as overhead tooling or robotic arms, can make mounting or wiring overhead sensors difficult in rework bays. This often necessitates manual spot checks or error-prone tracking methods, increasing the risk of missed arrivals and delayed repairs.

Solution:

  • M-GAGE sensors install directly into the floor, requiring no overhead space or mounting clearance, making them ideal for bays with suspended tooling or specialized equipment.
  • Self-powered and wireless, M-GAGE eliminates the need for cable runs or external power, simplifying deployment in constrained or retrofit environments.
  • Magnetic sensing reliably detects vehicle presence, replacing manual spot checks and ensuring consistent detection throughout rework operations.

Product Visual: Image of an M-GAGE sensor installed in a floor, alongside a DXM1200-X2R1 Industrial Controller.

Status Notification & Takt Time

Andon Status Display

Challenge: Without real-time visual status indication in rework bays, technicians rely on manual communication, delaying responses, increasing takt time, and reducing overall efficiency.

Solution:

  • The TL50 Tower Light, with five segments controlled by an LCA130T Andon box, provides at-a-glance status indication for parts needed, work complete, or technician requests.
  • The SD50 Status Display shows real-time status text, such as takt time, occupancy, or support requests.

Product Visual: Visuals of an SD50 Status Display, TL50 Tower Light, and LCA130T Andon Control Box for status indication.

Takt Time Visual Indication

Challenge: Providing takt time indication in rework bays offers technicians and planners real-time insight into cycle timing, improving coordination, reducing variation, and ensuring rework aligns with production goals.

Solution:

  • The WLS27 Pro Strip Light, using its timer option, provides visual takt time indication through progressive animations and color shifts, giving technicians an immediate sense of elapsed time.
  • The SD50 Status Display shows takt time in clear, bright-white characters legible from 10 meters, offering immediate visibility to maintain rework consistency and support efficient decision-making.

Product Visual: Images of an SD50 Status Display and a WLS27 Pro LED Strip Light used for takt time visualization.

Illumination for Inspection

On-Demand Inspection with Localized Control

Challenge: Completing inspection tasks directly within the rework bay requires adjustable lighting to match specific needs, such as checking paint, surface finish, or alignment defects.

Solution:

  • WLB72 LED Strip Lights provide bright, uniform illumination with high color accuracy, ideal for identifying paint flaws, surface inconsistencies, or alignment issues. An optional eye shield accessory enhances glare control and creates a zebra striping effect to improve visual contrast during inspection.
  • The K50 I/O Touch Control with Display offers technicians localized, glove-friendly control of light intensity, displaying real-time output values to match lighting levels to each task.

Product Visual: Images of a WLB72 LED Strip Light for inspection and a K50 I/O Touch Control with Display for localized lighting adjustment.

Collision Avoidance

Vehicle-Triggered Alert at Bay Exit

Challenge: A rework bay door opening onto a cross-traffic area poses a collision risk. Structural obstructions, driver distractions, and environmental noise reduce awareness as vehicles exit and cross pedestrian walkways.

Solution:

  • The Q90R2 Radar Sensor's 120° x 40° field of view reliably detects approaching vehicles exceeding a defined signal threshold at bay doors.
  • Two K100 Beacons with Audible, mounted outside the bay door, provide vivid, daylight-visible indication and can emit a continuous 2.5 kHz tone at 101 dB SPL to ensure warnings are noticeable in noisy environments.
  • The Q90R2 is easily configured using Banner's Measurement Sensor software, which provides a visual interface for defining the sensing field, tuning signal thresholds, and filtering targets based on motion and direction.

Product Visual: Illustration of a vehicle exiting a bay with a Q90R2 Radar Sensor detecting its movement and a K100 Beacon providing an audible and visual alert.

IIoT Integration with Snap Signal

Banner's Snap Signal hardware and software enable customers to instantly unlock valuable data from their equipment and increase productivity. This smart-factory portfolio creates an overlay network by capturing signals from existing and new devices, converting them to a unified protocol, and distributing them to monitoring platforms like SCADA systems, the cloud, or local PLCs/HMIs. The solution deploys easily, leveraging available information without disrupting existing controls, thereby saving costs, reducing downtime, and optimizing operations.

Diagram: A diagram illustrating the Snap Signal IIoT architecture, showing data flow from capture devices (sensors, controllers) through conversion and distribution to monitoring platforms (SCADA, cloud, HMI/PLC).

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