Introduction: The Evolution of Machine Guarding in Smart Manufacturing
In today’s automated manufacturing environment, ensuring worker safety is more complex—and more critical—than ever. Traditional guarding methods like fences and mechanical barriers are giving way to intelligent presence-sensing technologies. These innovations offer a perfect balance between safety, flexibility, and productivity.
Two standout solutions in this field are Keyence’s GL-S Series Safety Light Curtains and Inxpect’s 3D Safety Radar Systems. Together, these technologies are redefining what’s possible in machine safety by offering adaptable, precise, and fail-safe protection in even the most challenging environments.
1. Keyence GL-S Series Light Curtains: Compact and Capable
Compact Design for Tight Spaces
- Keyence’s GL-S light curtains come in slim (GL-SS) and flat (GL-SF) form factors—about half the size of traditional curtains. This makes them ideal for space-constrained applications like tight machine frames, robotic arms, or densely packed production lines.
Effortless Installation with Built-In Intelligence
- Thanks to Keyence’s One-Line System, these light curtains reduce wiring by up to 77%, simplifying installation and minimizing potential for wiring errors. Built-in mounting brackets further cut down setup time.
Status Indicators for Visual Safety
- GL-S units feature external status indicators with red, orange, and green LEDs, clearly signaling machine status or safe operating conditions. This boosts visibility and operational awareness—two essential components of safety culture.
Robust Safety Features
Keyence GL-S models are classified as Type 4 Safety Devices, offering high-performance protection for high-risk applications. Additional features include:
Edge-to-Edge Detection: No dead zones.
Built-in Muting and Interlock Functions: Eliminates need for extra modules.
External Device Monitoring (EDM): Adds system-level diagnostics.
Built for Harsh Environments
- With IP65/IP67 ratings, GL-S units withstand dust, water, and mechanical wear. Whether it’s a food plant or a metalworking facility, these curtains can handle tough conditions.
2. Inxpect 3D Safety Radar: Radar-Based Redundancy for Complex Zones
What Sets Inxpect Apart?
- Unlike light-based or mechanical sensors, Inxpect’s 3D radar systems use Frequency Modulated Continuous Wave (FMCW) radar to create volumetric protection zones. These are resilient against common industrial issues like smoke, dust, and debris.
True 3D Safety Coverage
- Inxpect detects even micro-movements like breathing, offering unmatched precision. It’s ideal for safeguarding dangerous zones where visual sensors might be obstructed or unreliable.
Dynamic Zoning and Real-Time Adjustments
- Through the Inxpect Safety Application, safety managers can define custom detection fields and adjust them on the fly. This gives facilities flexibility to adapt as workflows evolve.
First-in-Class Certification
Inxpect is the only 3D radar system certified for SIL2/PLd safety levels, making it compliant with ISO 13849 and IEC 62061.
3. Use Cases: Where Presence Sensing Shines
- Automated Guided Vehicles (AGVs)
- Inxpect radars can dynamically protect AGVs, stopping them in real time if personnel enter their path. Light curtains also assist at fixed points like docking stations.
Robot Work Cells
- Light curtains and radar zones around robot arms prevent unsafe access. In the event of an intrusion, the system halts movement immediately.
Packaging and Palletizing
- Safety systems need to protect yet remain flexible. GL-S curtains provide clear visibility, while Inxpect handles environments with debris or varying light conditions.
CNC and Press Machines
- Light curtains offer rapid response times critical for preventing contact with moving press components. Safety mats or interlocks can supplement them for layered protection.
4. Benefits to Safety Managers
- Reduced Downtime
- Both technologies help minimize unnecessary stops. With zone muting, diagnostics, and smart response times, equipment only halts when a true hazard occurs.
- Streamlined Compliance
- Meeting OSHA, ISO, and ANSI safety standards is easier with certified devices like GL-S and Inxpect. They reduce audit risks and demonstrate proactive safety planning.
- Improved Safety Culture
Real-time visual indicators and flexible zones promote safer work habits. Employees are more likely to follow protocols when they’re simple, visible, and intuitive.
5. Choosing the Right Presence-Sensing System
Factors to Consider:
| Feature | GL-S Light Curtains | Inxpect 3D Radar |
|---|---|---|
| Environment | Clean or moderately dusty | Harsh, dusty, smoky |
| Detection Field | Linear (2D plane) | Volumetric (3D zone) |
| Response Time | Milliseconds | Milliseconds |
| Installation | Requires direct line of sight | Handles visual obstructions |
| Certification | Type 4, ISO 13849-1 | SIL2, PLd, ISO 13849-1 |
For most facilities, using both technologies in tandem offers the highest degree of protection—light curtains for precision and radar for robustness.
6. ROI of Smart Safety Devices
Investing in advanced presence-sensing devices can yield significant returns:
Fewer Injuries = Reduced workers' comp claims
Less Downtime = Higher throughput
Improved Morale = Engaged and confident workforce
Audit Readiness = Lower regulatory risk
According to the National Safety Council, the average cost of a workplace injury is over $42,000. Even preventing a single incident can justify the investment.
7. Implementation Tips for Safety Managers
Start with a Risk Assessment: Evaluate hazards, workflows, and access points.
Choose the Right Devices: Don’t over- or under-specify—match tech to risk level.
Collaborate with OEMs and Integrators: Ensure proper installation and configuration.
Train Your Teams: Technicians and operators should understand both the function and importance of presence-sensing devices.
Maintain and Audit Regularly: Periodic validation keeps systems compliant and effective.
Conclusion: A New Standard in Safety
The future of machine guarding lies in intelligent, integrated, and intuitive safety systems. With technologies like Keyence’s GL-S Series Light Curtains and Inxpect’s 3D Radar, manufacturing facilities can achieve compliance, efficiency, and most importantly—protection for their people.
If you’re upgrading your machine guarding system or building a new one, consider implementing these next-gen tools for the smartest and safest results.
Need help selecting or installing presence-sensing technology in your facility? Contact PowerSafe Automation for a consultation or safety audit.
