> ## Documentation Index
> Fetch the complete documentation index at: https://wiki.codeandcompile.com/llms.txt
> Use this file to discover all available pages before exploring further.

# Smart Fill-Level solution from Banner Engineering

> Review of the Banner Engineering smart fill-level solution, with the presentation and source code from the video.

## From simple yes/no to true area sensing

![Smart Fill-Level solution from Banner Engineering](https://mintcdn.com/code-and-compile/AVgt2ILUleJ-6Ioq/images/Banner-Sensors-issues.png?fit=max\&auto=format\&n=AVgt2ILUleJ-6Ioq\&q=85\&s=eaac6eee12261632ba008c5ac1642e13)

* **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

[YouTube video player](https://www.youtube.com/embed/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

![Smart Fill-Level solution from Banner Engineering](https://mintcdn.com/code-and-compile/oJD_SnxirnRME6Em/images/k50z.png?fit=max\&auto=format\&n=oJD_SnxirnRME6Em\&q=85\&s=33204f4d834bb7eaa61b2e130443c531)

* **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

> [card] [Canva presentation](https://canva.link/0g9nq88sv18zr95)
>
> canva.link

## 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](mailto:rajvir@codeandcompile.com) or drop me a message on [LinkedIn](https://www.linkedin.com/in/singhrajvir/)


## Related topics

- [Smart Devices](https://wiki.codeandcompile.com/product-reviews/smart-devices/index.md)
- [Tasks and Solutions](https://wiki.codeandcompile.com/factory-automation/digital-twin/factory-io/tasks-and-solutions.md)
- [Analog or Digital Signal to IO-Link](https://wiki.codeandcompile.com/product-reviews/smart-devices/analog-or-digital-signal-to-io-link.md)
- [Visual Factory elements](https://wiki.codeandcompile.com/product-reviews/smart-devices/visual-factory-elements.md)
- [Banner SC10 Series](https://wiki.codeandcompile.com/factory-automation/safety-controller/banner-sc10-series/index.md)


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