Smart Factory Production Line Safety Interlock Control Solution
Pain Points & Requirements
In automotive assembly lines, safety interlock control is critical for personnel safety and equipment stability. A car assembly line requires real-time monitoring of safety door status, air pressure sensor data, and robotic arm position. If the safety door is open or air pressure is insufficient, the robotic arm must stop immediately and trigger an alarm to prevent accidents. Traditional PLC solutions suffer from slow response, poor scalability, and high costs, demanding smarter and more efficient alternatives.
Solution Configuration
Using Beilai IOy Series Multi-functional Programmable Remote I/O Modules, modular design enables precise control:
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Digital Control:
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DI channels monitor safety door status (closed = safe) and emergency stop signals.
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DO channels control alarm lights and robotic arm power, with forced shutdown upon emergency stop.
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Analog Acquisition:
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Real-time air pressure sensor monitoring (0-1MPa), triggering interlock if pressure falls below 0.6MPa.
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Motion Control:
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Pulse counting tracks robotic arm position, automatically slowing speed (AO outputs 4mA) upon exceeding limits.
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Core Features
✅ Multi-signal Integrated Control: Processes digital, analog, and pulse signals simultaneously with ≤10ms response time.
✅ Smart Logic Operations: Built-in IF-THEN conditions instantly halt operations and trigger alarms for safety door or pressure anomalies.
✅ Redundant Safety Design: Emergency stop button has independent priority to cut all outputs.
✅ Remote Monitoring: Data uploaded via Modbus TCP to SCADA systems for real-time visualization.
Implementation Results
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Enhanced Safety: 100% interlock activation for abnormal states, eliminating robotic arm malfunctions.
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Efficiency Optimized: Automatic speed reduction for pulse overruns reduces wear and extends equipment life.
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Cost Savings: Integrated modules replace traditional PLC+gateway setups, cutting deployment costs by 60%.
Typical Applications
? Automotive Assembly: Safety door interlocks, robotic arm coordination.
⚡ Electronics Manufacturing: High-speed equipment emergency stops and status monitoring.
?️ Logistics Sorting: Conveyor belt and robotic hand safety interlocks.
Why Choose Beilai IOy?
✨ Industrial-Grade Reliability: Operates at -40℃~85℃ with 2KV electrical isolation.
✨ Flexible Expansion: Supports free DI/DO/AI/AO combinations for complex scenarios.
✨ End-to-End Service: Full-cycle technical support from configuration to maintenance.
Contact Us
? 0086-755-29451836
Make Smart Factories Safer and More Efficient!
