> For the complete documentation index, see [llms.txt](https://wiki.codeandcompile.com/llms.txt). Markdown versions of documentation pages are available by appending `.md` to page URLs; this page is available as [Markdown](https://wiki.codeandcompile.com/product-reviews/smart-devices/smart-fill-level-solution-from-banner-engineering.md).

# Smart Fill-Level solution from Banner Engineering

In this page you will find the product review, get access to the presentation and source code used in the YouTube video

## From simple yes/no to true area sensing 📦

<figure><img src="https://1831238825-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2FLd2M9UNfMTnw9DjDdZJz%2Fuploads%2FZ76DPvhI2r5PUFm1TmJT%2FBanner%20Sensors%20issues.png?alt=media&amp;token=d2b36f0f-bf4b-4c02-85f5-3a3e51467103" alt=""><figcaption></figcaption></figure>

* ❌ **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

{% embed url="<https://youtu.be/cJggykBWS00>" %}

## 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 🤯

<figure><img src="https://1831238825-files.gitbook.io/~/files/v0/b/gitbook-x-prod.appspot.com/o/spaces%2FLd2M9UNfMTnw9DjDdZJz%2Fuploads%2Fn3eRz1o9ImfZ2XM0F6om%2Fk50z.png?alt=media&amp;token=0a2bbdfe-4e4b-4f20-b507-abb513a0f291" alt=""><figcaption></figcaption></figure>

* 🔲 **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 🗒️

{% embed url="<https://canva.link/0g9nq88sv18zr95>" %}

## ♥️ Work With Me

I regularly test **industrial automation and IIoT devices**. If you’d like me to **review your product** or showcase it in my courses and YouTube channel:

📧 Email: <rajvir@codeandcompile.com> or drop me a message on [LinkedIn](https://www.linkedin.com/in/singhrajvir/)