In the world of modern manufacturing, machine safety is no longer limited to physical barriers and emergency stops. Today, connected safety systems are giving operators real-time visibility into risks, machine behaviour and potential failures before incidents occur.
“There’s been a significant shift in the approach to machine safety,” says Geoff Thorpe, Managing Director of TURCK Australia and New Zealand. “Today, manufacturers need integrated safety networks that improve visibility across operations and make predictive safety possible - without compromising efficiency.”
According to Geoff, ease of use is a critical part of this evolution. Pointing to Rapid Global’s Australian Workplace Safety Market Research report, he notes that many organisations still face challenges with safety systems. “This report established that only 34% of warehousing managers and 41% of manufacturing frontline workers agree that their safety systems are modern and easy to use. The report warns that when systems are difficult to use, workers may bypass them or resort to unsafe workarounds.”
When safety systems become intelligent
While the use of components such as safety scanners, switches and sensors is not new, their integration into automation networks using technologies such as IO-Link, ISD (In-Series Diagnostics) and HMIs is currently transforming machine safety as we know it.
“These systems provide real-time visibility into machine stoppages, faults and operator interactions, helping teams identify risks earlier and respond proactively,” explains Geoff. “Safety devices such as light curtains and switches make it easier for people to interact safely with machines by slowing equipment or warning operators of potential hazards.” He adds that when combined with IO-Link and ISD technologies, manufacturers and warehouse operators gain far greater visibility and control across complex systems making it easier to identify operational or safety risks earlier and take action.
Banner Engineering’s RSio Remote Safe I/O is one example of how connected safety is transforming machine protection. Available from TURCK (the official local distributor of Banner Engineering solutions) it features six inputs for safety devices as well as configurable safety outputs, enabling manufacturers to divide machines or production areas into independently monitored and controlled sections without requiring specialised equipment or complex cabling. In addition, the RSio is IP67-rated for flexible, out-of-cabinet installations, making it even easier to place smart diagnostics where they are needed most.
In a complex material handling or manufacturing application, the RSio enables manufacturers to create independent safety zones, where different conveyor lines to be monitored and stopped independently. “With this intelligent device, there’s no need to shut down an entire line every time a hazard is detected as it isolates problems. The instant diagnostics help factory teams fand fix issues much faster, reducing downtime.”
Choosing the right solutions
As manufacturers modernise their safety infrastructure, selecting scalable and user-friendly technologies becomes increasingly important. Geoff encourages manufacturers to look for solutions that will integrate easily into existing infrastructures (even complex automation systems) and which are flexible and scalable.
As the official local distributor of Banner Engineering solutions, TURCK offers a comprehensive range of machine safety technologies, including light curtains, laser scanners, safety controllers, switches and energy control solutions, alongside complementary IIoT technologies. “These are modular, flexible and user-friendly, designed for manufacturing systems of all sizes. No matter how complex your production or your warehouse system is, we’ve got a safety solution that will adapt to the requirements and evolve with your operations,” says Geoff.
“Connected, sensor-based safety systems provide manufacturers with real-time operational insight, helping teams identify hidden risks earlier while improving productivity, uptime and compliance,” concludes Geoff.
More information available at: https://www.turck.com.au/en/
Turck Australia and Turck New Zealand are also proud distributors of Banner Engineering - https://www.bannerengineering.com/.
