Posted to News on 11th Dec 2024, 09:35
Ensuring operator safety and efficiency on automated assembly benches
A challenge in automated assembly systems is ensuring the protection and safety of the operators without compromising high product throughput or quality. Assembly benches provide many manufacturing businesses with flexible and efficient processes, but they can be challenging to implement with robust automation and machine safety solutions, as the experts at PLUS Automation explain.
(See PLUS Automation at FoodManufacturing.Live, 15 October 2025, on stand 49)
Part of the automation challenge with assembly systems is creating a safe and functional work environment that reduces the risk of unauthorised access, accidents and downtime. A robust and reliable safety solution prevents issues from arising that can negatively impact production levels, as well as the quality of work and the well-being of workers.
Typical machine safety challenges for an automated assembly bench include:
Access control: Preventing unauthorised entry during the work cycle is critical to avoid accidents.
Safety functions management: Integrating the start, stop and reset function is essential to reduce inefficiencies and prevent damage.
Safe human-machine interaction: The use of intuitive and clear displays to show instructions and working parameters is essential to ensure safe collaboration between operator and machine.
ReeR offers machine safety solutions suited to all types and sizes of machines, from complex multi-stage production lines to simple machines. Whilst assembly benches are at the simpler end of that continuum, they are a good example of the need for high performance and reliability. Typical ReeR Safety products on an automated assembly bench include:
EOS4 903 X Safety Light Curtain: A typical assembly bench would use a protected height of 910 mm and a resolution of 30 mm to detect any interference and immediately stop the work cycle, protecting operators' hands.
Models are available with integrated safety functions such as self-monitoring static outputs, control of external contactors (EDM), and selectable automatic or manual restart. 2 safety PNP static outputs are provided and connection and installation is easy using the M12 connectors and unshielded cables of up to 100 metres.
These curtains are easy to install, require no programming and offer operation in manual or automatic modes. The absence of a blind zone on one side of the barriers further increases the system's effectiveness.
MOSAIC M1 Safety Controller: The M1 safety controller can operate as the hub in a larger safety solution on a complex machine by using expansion units or as a standalone unit. The unit in standalone mode can connect with up to 4 safety devices, for example, a safety light curtain, an e-stop, a magnetic door sensor and a two-hand switch.
Combining all of the safety functions required on an assembly bench or small machine into one unit optimises control of the processing cycle, minimises downtime, and reduces the amount of cabling.
PLUS Automation can help you #MakeSenseofSensors, solve applications, improve machine performance and reliability, and reduce costs using ReeR Safety's machine safety light curtains, safety sensors, safety controllers and measurement light grids.
