Robot Safety Components for Industrial Automation

Which Robot Safety Product Fits Your Application?

Start with one simple question: What needs to be protected?

Do you need to monitor an open area around the robot? Is there a fixed entrance to the cell? Does a guard door need to be checked? Or should a moving surface react when it touches a person?

The answer helps narrow down the right product group.

The products in this category solve different parts of a robot safety system. A scanner, switch, mat, or light curtain is therefore not directly comparable with a safety controller or complete bundle.

Safety Laser Scanner or Safety Light Curtain?

Both products detect people without physical contact, but they monitor different spaces.

A safety laser scanner monitors an area. It is often used around open robot cells, palletizing stations, loading areas, and other spaces where people may approach from more than one direction.

A safety light curtain creates a straight detection field between a transmitter and receiver. It is commonly used at entrances, machine openings, loading points, and manual workstations.

Choose a scanner when the work area is open or people may approach from different sides.

Choose a light curtain when access happens through a clear opening.

When Is a Safety Mat Useful?

A safety mat detects when a person steps onto a defined floor area.

It can be used:

• In front of a robot cell

• At a manual loading station

• In front of a machine

• Inside a limited work area

• Around a transfer point

The SENTIR mat visible in the product grid belongs to this product group.

Before selecting a mat, check:

• The size and shape of the floor area

• Whether a person could walk around the mat

• Floor conditions

• Expected mechanical load

• Dirt or moisture in the work area

• Required cables and evaluation hardware

A safety mat is most useful when the area is easy to define and cannot be entered without stepping on it.

When Is a Safety Contact Bumper Used?

A contact bumper is mounted on a moving surface or possible collision point. When the bumper is pressed, it sends a signal to the connected safety control system.

Contact bumpers can be useful for:

• Moving robotic equipment

• Mobile or adjustable systems

• Possible crushing points

• Moving machine parts

• Areas where contact cannot be fully avoided

The SENTIR bumper 4 robotics in the RBTX assortment is designed for this type of application.

Before purchasing, check where the bumper will be mounted, how much space is available, and how the signal will be connected to the rest of the system.

When Does a Robot Cell Need a Safety Switch?

A safety switch checks whether a guard door, cover, or access panel is closed.

When the door opens, the switch sends a signal to the safety controller. The controller can then start the planned response.

A non-contact safety switch such as the SICK STR1 may be useful when:

• A guard door is opened regularly

• A compact switch is required

• Mechanical wear should be reduced

• Several doors need to be monitored

• A small mounting tolerance is helpful

Before purchasing, determine whether the system only needs to detect an open door or whether the door must also remain locked during operation.

A basic safety switch detects the door position. It does not automatically provide locking.

What Do Safe I/O and Safety Controllers Do?

A scanner, light curtain, switch, mat, or bumper detects an event. It does not normally control the complete response by itself.

The signal is usually sent to a safety relay, safe I/O module, or safety controller.

A simplified safety function works like this:

1. A sensor detects a person, open door, or contact.

2. A safe control component evaluates the signal.

3. The robot or machine performs the planned response.

Safe control components become more important when several devices need to work together.

Examples include:

• Laser scanner and emergency stop

• Several guard doors

• Robot and conveyor

• Light curtain and machine

• Several monitored areas

• Different operating modes

The RBTX assortment includes secure Ethernet I/O from Turck and the SSP Safety Simplifier for this part of the system.

When Is a Safety Bundle a Good Choice?

A safety bundle combines several related components in one package.

The IDEC Small, Medium, and Large Safety Bundles visible in the category are useful for applications that need more than one safety component.

A bundle may be suitable when:

• You are building a compact robot cell

• No safety controller is currently available

• Several related components are required

• You prefer one package instead of selecting every part separately

• The included parts match the planned application

Before purchasing a bundle, check:

• Which parts are included?

• What task is the bundle intended to solve?

• How many devices can be connected?

• Does it fit the robot and control system?

• Are cables and connectors included?

• Is additional hardware required?

• Will the system need to expand later?

The largest bundle is not automatically the best option. Select the package that covers the required task without adding unnecessary components.

Industrial Robot Safety and Cobot Safety

Traditional industrial robot safety often uses physical separation, such as fencing with monitored access doors. Depending on the layout, light curtains or laser scanners may also be used at loading points and open sides.

A collaborative robot may include built-in safety functions, but that does not mean every cobot application works without additional protection.

Risks may still come from:

• A sharp or pointed gripper

• A heavy workpiece

• High movement speed

• Crushing points

• Hot parts

• Cutting or welding processes

• Falling products

• Nearby machines or conveyors

The right collaborative robot safety solution depends on what the robot is doing, not only on the robot arm.

For cobot safety, the gripper, workpiece, movement, workspace, and nearby equipment should all be considered together.

What Should You Check Before Buying?

Which Area Needs Protection?

First, identify where people can approach the equipment.

This may include:

• The front of the robot

• An open side of the cell

• A loading station

• A guard door

• A walk-in area

• A conveyor opening

• A maintenance access point

H3: What Needs to Be Detected?

Does the Product Fit the Control System?

Not every safety component connects directly to every robot controller or PLC.

Check:

• Available safety inputs and outputs

• Required cables and connectors

• Whether an additional evaluation unit is needed

• Supported communication interfaces

• Available robot safety functions

• Required configuration software

• Whether additional modules are needed

A suitable sensor may still require a safety relay, safe I/O module, or safety controller.

Which Additional Parts Are Required?

The product shown in the grid may not be the complete solution.

Additional items can include:

• Cables

• Connectors

• Mounting brackets

• Safe I/O modules

• Safety relays

• Control cabinet components

• Protective housings

• Configuration software

Include these parts when comparing product prices.

What Is Functional Safety in Robotics?

Functional safety in robotics describes how sensors, control components, and robot functions work together.

For example:

1. A light curtain detects that a person has entered an opening.

2. The safety controller receives the signal.

3. The robot performs the planned response.

This means that the sensor is only one part of the complete system. The signal path, control hardware, robot controller, and connected equipment also need to work together.

The same principle applies to broader machine safety in robotics, especially when robots are connected to conveyors, machines, doors, and manual workstations.

How to Select Robot Safety Components

Use this simple order:

1. Identify where people can approach the robot.

2. Decide what needs to be detected.

3. Select the matching product type.

4. Check whether safe control hardware is already available.

5. Confirm that the product connects to the robot or PLC.

6. List the required cables, brackets, and additional modules.

7. Compare an individual component with a complete safety bundle.

8. Have the full setup reviewed by a qualified safety specialist.

This process helps narrow down the available products without starting with unnecessary technical details.

What Does a Robot Safety System Cost?

The total cost depends on more than the price of the sensor.

A low-cost sensor may require additional hardware that increases the total project cost.

A safety bundle may be more economical when several included parts are required. An individual sensor may be the better option when the cell already has suitable safe control hardware.

Compare the complete setup, not only the product shown in the grid.

Frequently Asked Questions About Robot Safety

What Safety Equipment Does a Robot Cell Need?

That depends on the cell layout, robot movement, tooling, and access points. Common products include laser scanners, light curtains, safety switches, mats, bumpers, safe I/O, and safety controllers.

What Is the Difference Between a Laser Scanner and a Light Curtain?

A laser scanner monitors an area. A light curtain monitors a fixed opening or access point.

When Is a Safety Mat Suitable?

A safety mat is suitable for a clearly defined floor area. It detects when a person steps into that area.

What Is a Safety Contact Bumper Used For?

A contact bumper detects physical contact with a moving surface. It can be used where possible contact cannot be fully avoided.

Does a Cobot Always Need Additional Safety Equipment?

Not always. The gripper, workpiece, movement, process, and surrounding equipment should also be considered before selecting the safety solution.

What Is a Safety Bundle?

A safety bundle contains several related safety components in one package. It can simplify selection for a compact or clearly defined application.

Can Every Safety Component Connect to Every Robot?

No. Connections, control architecture, software, and available safety functions need to match the specific robot controller.

Is One Safety Sensor Enough?

Not always. A sensor often needs safe evaluation hardware, suitable wiring, and a defined response from the robot or machine.

What Should I Clarify Before Choosing a Safety Product?

Define where people can approach the robot, what the component needs to detect, and which control hardware is already available. Also check whether cables, brackets, safe I/O, or additional evaluation hardware are required.