Machine safety with radar sensors
To ensure machines and installations operate safely, hazardous zones around moving parts are monitored using safety components such as safety light curtains, laser scanners or safety mats. These systems ensure that a machine is automatically brought to a safe state when a person enters a hazardous area.
In certain industrial environments, however, optical systems can be sensitive to influences such as dust, water, smoke, vapour, wood chips or moisture. This can lead to unstable protection or unwanted emergency stops or machine stops.
Radar safety as an alternative
In such situations, radar safety offers a reliable alternative. Because radar is a non-optical detection technology, its performance is hardly affected by contamination or environmental influences. As a result, detection remains stable, even under harsh industrial conditions.
The radar safety system from Inxpect detects access to or presence of operators in hazardous areas. Detection and warning zones can be dynamically configured, allowing the system to be precisely tailored to the application. The radar technology responds only to people and ignores small objects and environmental influences, preventing unnecessary interruptions.
Series and general features
Inxpect radar sensors are divided into three series. Each series is developed for a specific type of application and detection method.
| Cuboid Radar sensors with configurable 3D detection fields (cuboids). The detection area is built up from multiple spatial blocks, allowing monitoring to be precisely adapted to the machine geometry. |
Plug&Safe Pre-configured radar sensors for fast protection of hazardous zones. Depending on the model, they are used for safeguarding (virtual light curtain) or presence sensing. |
Classic & Corridor Radar sensors with a configurable FOV (Field of View). The detection field can be configured as a wide detection zone or as a narrow corridor for aisles, transport lines or passages. |
General features
Despite the different series and application areas, Inxpect radar sensors share several important technical characteristics. These features ensure reliable detection, easy integration and broad applicability within industrial machine safety systems.
| 60 GHz radar technology Reliable detection of people, even in environments with dust, smoke or moisture. |
Protection rating up to IP67 Suitable for industrial environments, additional protective accessories optionally available. |
| Safety level up to SIL 2 / PL d / Cat. 3 Suitable for use in machine safety systems. |
Flexible system architecture Multiple sensors can be combined within a single system. |
| USB, Ethernet, PROFIsafe, FSoE and CIP Safety interfaces Easy integration and configuration within existing installations. |
Detection range up to approximately 9 metres Depending on sensor type and configuration. |
Inxpect S202A-MC series radar sensors with 3D detection zones
The Inxpect S202A-MC series enables highly flexible configuration of safety zones. The radar sensors detect people and objects in three dimensions. This allows hazardous areas around machines, robots and installations to be reliably monitored, even in harsh industrial environments.
Configurable 3D detection zones (cuboids)
The S202A-MC sensors use so-called cuboids. A cuboid is a three-dimensional detection zone that can be freely positioned in space, with adjustable shape, dimensions and position. Instead of one large generic detection field, safety zones can be precisely aligned with the actual hazardous areas of a machine or installation.
Multiple cuboids can be defined within a single radar sensor. Depending on the model, one or more separate 3D detection zones can be configured:
Dynamically switchable detection fields
Dynamically switchable fields enable applications where detection zones can be activated or deactivated depending on the situation, for example during infeed and outfeed of products. This often makes it possible to safeguard the same installation with fewer sensors, simplifying installation and reducing cabling and mounting points.
Inxpect Plug&Safe Line – Maximum safety, minimum effort
The Plug&Safe Line from Inxpect consists of two compact radar sensors for securing hazardous areas. These sensors combine powerful radar performance with simple configuration and short installation times. They are suitable for industrial environments where reliability is crucial.
Safeguarding / Presence sensing
The S202A-MS is designed for safeguarding and acts as a virtual light curtain. As soon as someone enters the monitored zone, the sensor immediately disables hazardous motion. Only two parameters are required for configuration: height and length.
The S202A-MV is designed for presence sensing and prevents machine restart as long as someone is present in the monitored zone. The sensor is easily configured using three parameters: height, length, and width.
Reliable operation in any environment
Both models operate reliably in environments with dust, smoke or other visual disturbances, where optical sensors often fall short. Installation is quick and intuitive via Inxpect Safety Studio. The sensors comply with SIL 2 (IEC/EN 62061), PL d (ISO 13849) and IEC TS 61496-5 standards, offering a safe and compliant solution for a wide range of applications.
Flexible FOV configuration for radar sensors
Inxpect radar sensors offer extensive possibilities to adapt the FOV (Field of View) to the application. By configuring the detection area precisely, the sensor can focus on the area where objects are actually expected. This increases detection accuracy and reduces false detections.
Corridor FOV and asymmetrical FOV
For applications with narrow passages or aisles, the Corridor FOV can be used. The radar’s field of view is deliberately narrowed so that only the area in front of the sensor is monitored. This is useful in warehouses or at passages where detection outside the path is undesirable.
In addition, the sensors offer an asymmetrical FOV. The detection area is not distributed symmetrically, but can be extended or limited in a specific direction. This allows the radar to focus on a specific machine part, transport line or walking route, while minimising detections outside this area.
Dynamically adjustable detection area
The detection area of the radar sensor can be dynamically adjusted in steps of 5° over a wide range. This allows the FOV to be precisely tuned to the application, for example in narrow passages, production lines or specific movement directions.
Software for radar safety
Inxpect Safety Studio is the configuration and validation software for Inxpect safety radar systems. The software can be installed on any PC and is used to configure, monitor and validate the complete radar safety system.
With the software, detection areas can be configured, system parameters can be set and system performance can be validated. Inxpect Safety Studio therefore forms an integral part of every Inxpect radar safety system.
System configuration
All parameters of the radar sensors and the control unit can be easily configured. Machine layouts can also be imported, including 3D STEP files of the machine. This allows detection areas to be configured directly in relation to the actual machine geometry.
System status monitoring
The software provides insight into the status of the complete system. This includes the status of the control unit, the individual sensors and the inputs and outputs.
System validation
Inxpect Safety Studio supports the validation process of the safety system. Users are guided step by step in checking the configuration and system operation, after which validation reports can be generated.
Control units for processing and safety
Inxpect radar sensors are combined with dedicated controlunits that process detection data and translate it into safe signals for machine control. The controlunit determines whether a situation is safe or whether the machine must be brought to a safe state.
System architecture and rugged versions
Multiple radar sensors can be combined within a single system. The controlunit manages the different detection and warning zones and ensures communication with the safety control system.
For industrial applications, ruggedized controlunits are also available. These versions are designed for use in harsh environments and provide a robust solution for applications where vibration, temperature variations or industrial contamination play a role.
Set up complete safety system with safety PLC
The power of radar safety lies in the collaboration between advanced systems such as those from Inxpect and safety PLCs like the Reer Safety Mosaic M1. By integrating these systems, a complete safety system is created that detects both objects and people in hazardous areas and activates the appropriate safety measures.
Inxpect's radar safety system acts as a sensor that accurately identifies people and objects in high-risk zones. Once a dangerous situation is detected, the system sends this information via the Inxpect controller to the safety PLC. This Mosaic safety PLC analyzes the data and takes appropriate actions to minimize risk, such as stopping machinery or activating warning signals.
The Inxpect controller supports protocols such as PROFIsafe, EtherCAT Safety, and Modbus, ensuring seamless and reliable data exchange between the systems.
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Safe Operation
Safeguarding hazardous zones with radar sensors is just one example of the solutions fortop offers within the Safe Operation knowledge area. This domain focuses on safety around machines and installations. In addition to radar sensors, the Safe Operation programme includes:
* Safety light curtains
* Safety photocells
* Safety mats
* Non contact safety switches
* Safety PLCs
* Safety switches
* Signal lights
Machine safety at fortop
With this wide range within Safe Operation, you will always find a suitable solution for safe industrial processes in your sector: from machine building to the production and processing industry.
