From simple yes/no to true area sensing
- The hidden problem: most sensors on the shop floor answer only one question — is something there, yes or no? A single point can only report a single point, so a hole, an odd shape, or an uneven load triggers a false “full” signal → stopped lines and wasted product.
- The idea: climb the measurement ladder — from on/off detection, to how much, to a visual signal, all the way to full-area multi-point sensing.
- The fix: replace one beam with 64 measuring points using the Banner K50Z.
LIVE Demo
The Sensor Ladder
- QS18 — all-purpose photoelectric sensor, 400 mm range. Simple on/off level detection paired with an S15L visual status indicator (green = clear, orange = set point reached).
- Q20 — time-of-flight sensor, 3 m range. Tells you how full, not just yes/no. Drives a WLS strip light (via LC25 controller) for an at-a-glance fill gauge — no HMI, no PLC.
- Q5X — multi-function laser sensor, up to 10 m. IO-Link, dual-channel, PFM/PNP/pulse-pro outputs. Paired with the K100 programmable display beacon to show live level, status text, and tower-light colors.
The Single-Point Limitation
- Every single-point sensor (QS18, Q20, even the mighty Q5X) shares one weakness: one beam, one point.
- Adding more single-point sensors = more cables, more cost, more things to fail and program.
- The better answer is measuring the whole area with one device.
K50Z — Advanced Multi-Point Detection
- 3D time-of-flight across an 8×8 grid = 64 measuring points in a single sensor.
- Measures every spot in the bin and reports the average (or nearest) distance — so an odd-shaped or gapped load is still read correctly.
- Splits its field of view into two zones, doing the job of two sensors — half the hardware, full coverage.
- Banner software walkthrough: 3D/2D views, pixel filtering, Region of Interest (ROI) selection, set points, hysteresis (object vs. background reference), and window mode.
- PFM / pulse-pro output turns the measurement into a frequency signal (100–600 Hz) — the key to showing a live fill percentage on a display like the K100 or SD50.
Full Build: K50Z + IO-Link + Node-RED
- K50Z → DXMR110-8K IO-Link master → SD50 display, powered at 24 V.
- The IO-Link master runs the logic directly, no extra PLC required.
- Node-RED handles the scaling math and a live dashboard: 0% (empty) → orange alert → blinking red at 100%.
Key notes
Canva presentation
canva.link