Pinnacle Systems Inc.
Safety workers strategizing in an industrial plant, ensuring proper implementation of safety controls to protect workers and enhance machine safety.

Top 8 Safety Controls for Industrial Automation in 2025

January 27, 2025 Colton Hower Safeguarding 0

Industrial automation continues to evolve, with new technologies driving efficiency and productivity across sectors like manufacturing, food processing, and automotive production. As automation becomes more sophisticated, ensuring machine safety and compliance with safety regulations remains a priority for facility managers. Safety controls play a crucial role in protecting workers, equipment, and operational integrity.

This article explores the top eight safety controls for industrial automation in 2025, highlighting their features, applications, and benefits for modern facilities.

 

What Are Safety Controls?

Safety controls are devices and systems designed to monitor, control, and mitigate risks in automated environments. They prevent accidents by detecting hazards, stopping machinery, and ensuring safe operation. In industrial automation, safety controls are essential for protecting workers, avoiding costly downtime, and maintaining compliance with regulations such as OSHA Machine Guarding Standards and ISO 13849.

Key Features of Modern Safety Controls:

  1. Real-Time Monitoring: Continuously track equipment performance and worker presence.
  2. Automation Integration: Seamlessly integrate with programmable safety controllers and PLCs.
  3. Fail-Safe Design: Automatically shut down systems during faults or breaches.
  4. Scalability: Adapt to the needs of small facilities or large industrial plants.

1. Safety Light Curtains

Close-up of safety light curtains installed around robotic machinery, creating an invisible barrier to detect breaches and stop operations instantly.

Safety light curtains are sensor-based devices that create invisible barriers around hazardous machinery. These curtains consist of a transmitter and receiver, emitting infrared beams that stop machines if the beams are interrupted.

Applications of Safety Light Curtains:

  • Robotic Systems: Protect workers from entering dangerous zones during robotic operations.
  • Press Machines: Ensure operators stay clear of pinch points.
  • Automated Conveyors: Prevent collisions by stopping conveyors when obstructions are detected.

Example: A metal fabrication plant installed safety light curtains around robotic welding stations, significantly reducing accidents and downtime.

Key Benefits:

  1. Hands-Free Safety: Non-contact detection keeps operations seamless.
  2. Flexible Design: Suitable for a wide range of machinery and layouts.
  3. Quick Response: Immediate shutdown when barriers are breached.

Safety light curtains are a proven solution for enhancing worker protection and improving workflow efficiency. Learn more about their operation and installation here.

2. Emergency Stop Controls

Emergency stop controls, or E-stops, provide a manual safety mechanism that allows workers to halt machinery instantly in case of danger. These controls are critical in preventing accidents and minimizing damage during emergencies.

Features of Emergency Stop Controls:

  • Highly Visible: Red buttons or pull cords for easy identification.
  • Mechanical or Electrical Options: Adaptable to different machine types.
  • Direct Connection to Safety Circuits: Ensures immediate response.

Example: In a food processing plant, E-stops installed along production lines allow operators to shut down conveyors during maintenance or malfunctions.

Benefits of Emergency Stop Controls:

  1. Instant Response: Quickly mitigate risks during unexpected events.
  2. Worker Empowerment: Give personnel control over safety.
  3. Regulatory Compliance: Meet requirements from OSHA and ANSI.

3. Safety Mats

Pressure-sensitive safety mats placed around industrial equipment, triggering machine shutdowns when stepped on to protect workers.

Safety mats are pressure-sensitive devices placed around machinery to detect foot traffic in hazardous zones. These mats trigger an immediate stop when someone steps into the protected area.

Where Safety Mats Are Used:

  • Robotic Cells: Secure areas where robots interact with workpieces.
  • Packaging Systems: Protect workers near high-speed equipment.
  • Press Operations: Stop machinery if operators move too close.

Advantages of Safety Mats:

  1. Comprehensive Coverage: Protect large or irregularly shaped areas.
  2. Ease of Use: Simple installation and minimal maintenance.
  3. Customizable: Tailored sizes and shapes to fit specific zones.

4. Programmable Safety Controllers

Programmable safety controllers (PSCs) act as the central hub for managing multiple safety devices in a facility. These controllers process data from sensors, light curtains, safety mats, and E-stops, triggering appropriate responses in real time.

Why Programmable Safety Controllers Are Essential:

  • Simplified Integration: Manage all safety components through a single system.
  • Custom Logic Programming: Adapt to unique safety requirements.
  • Diagnostics and Reporting: Provide actionable insights into system performance.

Example: A manufacturing facility upgraded to a PSC to streamline its safety network, connecting E-stops, light curtains, and interlocks for improved efficiency.

Key Benefits:

  1. Enhanced Safety Management: Centralized control for multiple devices.
  2. Reduced Complexity: Simplify wiring and programming.
  3. Scalability: Easily add new devices as needs evolve.

5. Interlock Switches

Interlock switches securing an access gate near hazardous machinery, ensuring the system remains inactive until the gate is closed.

Interlock switches are mechanical or electronic devices that secure access points like gates and doors. They prevent machinery from operating when access points are open, ensuring worker safety during maintenance or troubleshooting.

Types of Interlock Switches:

  • Mechanical Interlocks: Use physical mechanisms to secure doors.
  • Non-Contact Interlocks: Use magnetic or RFID sensors for secure, contactless operation.

Example: In a pharmaceutical facility, interlock switches were installed on cleanroom doors to prevent unauthorized access while robotic systems were running.

Advantages of Interlock Switches:

  1. Operator Safety: Prevent accidental exposure to moving parts.
  2. System Integrity: Ensure machines remain inactive during maintenance.
  3. Compliance: Meet ANSI B11.19 requirements for interlock devices.

6. Laser Scanners

Laser scanners use advanced technology to map safety zones and detect movement around machinery. They provide flexible and customizable perimeter guarding, ideal for dynamic environments.

Applications of Laser Scanners:

  • AGVs (Automated Guided Vehicles): Detect obstacles and navigate safely.
  • Robotic Arms: Protect zones that change based on robot movement.
  • High-Traffic Areas: Monitor worker activity near automated systems.

Example: A logistics warehouse implemented laser scanners to monitor robotic arms and AGVs, improving safety without hindering operations.

Benefits of Laser Scanners:

  1. Dynamic Protection: Adjust detection zones in real time.
  2. High Precision: Detect small objects or movements.
  3. Versatility: Suitable for complex environments.

Laser scanners offer precision and adaptability for protecting dynamic environments. For insights on their role in industrial safety, check out this article.

7. Two-Hand Control Systems

Operator using two-hand controls to safely activate industrial machinery, ensuring both hands are positioned away from dangerous areas.

Two-hand control systems require operators to use both hands simultaneously to activate machinery. This ensures operators are positioned safely before dangerous equipment starts operating.

Where Two-Hand Controls Are Used:

  • Metal Stamping Machines: Prevent hands from entering pinch points.
  • Woodworking Equipment: Protect operators from cutting blades.
  • Injection Molding Machines: Ensure safe positioning before operation.

Advantages:

  1. Preventing Hand Injuries: Keeps hands away from dangerous zones.
  2. Operator Control: Ensures safety before activation.
  3. Simplicity: Easy to integrate and operate.

 

8. Perimeter Guarding Systems

Perimeter guarding involves creating physical and sensor-based barriers around robotic systems and hazardous machinery. These systems secure large areas, ensuring only authorized personnel can access dangerous zones.

Key Components of Perimeter Guarding:

  • Physical Barriers: Fences and interlocked gates.
  • Sensors: Safety light curtains and laser scanners.
  • Access Control: RFID badges or keyed switches for authorized entry.

Example: An automotive plant used perimeter guarding to protect workers from robotic welding arms, reducing incidents by 40%.

Why Perimeter Guarding Matters:

  1. Enhanced Safety: Prevents accidental access to hazardous areas.
  2. Flexible Designs: Adapt to various layouts and workflows.
  3. Regulatory Compliance: Meet OSHA and ISO requirements for machine guarding.

 

Looking Ahead to Safety in Automation

As industrial automation continues to advance, safety controls will play an increasingly vital role in ensuring machine safety and operational efficiency. From safety light curtains to programmable safety controllers, these systems protect workers, reduce downtime, and help facilities meet rigorous safety standards.

By adopting these top eight safety controls in 2025, facilities can future-proof their operations and ensure a safer working environment.

Explore Pinnacle Systems’ range of safety products to find solutions tailored to your facility’s needs.