Reduce risks, enhance safety

INDUSTRIAL ROBOTS play a critical role in manufacturing due to their ability to handle heavy components, high forces, and repetitive operations. As a result, more robots are being used in manufacturing lines to improve productivity, quality, and consistency. However, when operators need to access the areas where these robots operate, they face significant hazards. Unrestricted or unauthorised access can result in crushing, impact, or entanglement injuries, potentially causing severe or fatal harm.

To address these risks, access control solutions such as interlocks on movable guards are essential. Operators should only enter safeguarded spaces once the hazards are in a safe state. Two case studies below from Automazioni Industriali Capitanio (AIC) and Intec Robotics highlight how robust access control strategies are applied in different contexts while enhancing operator safety.

Upgrade to networked solutions

AIC is a global manufacturer of automation systems, process control, and mechatronic solutions for the steel industry. The company undertakes both greenfield and revamping projects, focusing on rolling mills and long product lines, and delivers customized solutions to clients in over 65 countries.

Within its steel processing applications, AIC’s robotic systems handle tasks such as tagging semi-finished or finished metal products, including bars and coils. These environments involve heavy components and continuous operations, creating potential hazards when operators need access to the robot cells.

To address these challenges, AIC has implemented amGardpro interlocks from Fortress Safety. Upon requesting access, operators are only allowed into the robot cell once the robot has completed its cycle and reached a controlled stop. Guard locking mechanisms hold movable guards closed until safety conditions are verified. 
Initially, AIC relied on hardwired interlocks, but over time they transitioned to networked interlocks that communicate via PROFINET and EtherNet/IP. This upgrade simplified wiring, improved diagnostics, and allowed faster commissioning, while maintaining robustness for harsh steel plant environments. Additional features, such as pushbuttons, emergency stops, and escape releases, were also included.

“We started with the hardwired solution," says Michele Serlini, technical director – mechatronics unit, AIC. "Then over the years we evolved, and we tested the first networked interlocks, and lately we've been using almost exclusively those because they greatly simplify wiring and improve diagnostics, still maintaining the proven robustness and reliability.” 

All controls in one unit

Intec Robotics is a machine builder that designs and builds state-of-the-art standard and custom robotic machines for surface finishing used to automate processes like polishing, grinding, linishing, and deburring. These machines operate at high speeds with intense forces and abrasive tools, creating hazards when operators need access for setup, adjustments, or troubleshooting. Risks include exposure to moving parts, unexpected start-up, and entrapment.

To protect operators, Intec Robotics needed interlocks that provide flexibility and reliability to adapt to different machine designs across various industries. The tGard range stood out among many products. With its slim 40 mm profile, the tGard allows installation in narrow mounting areas. Furthermore, they integrate pushbuttons, emergency stops, and escape releases into a single unit, helping boost efficiency and reduce errors.

Over time, Intec Robotics has adopted tGard in various configurations. Notably, the company was one of the first to adopt the tGard HLC (High Level Coded) solution, which include an RFID actuator for protection against defeat, high misalignment tolerance, and guard monitoring up to PLe. Some machines use personnel keys, which operators keep while inside the safeguarded area. The machine cannot restart until all keys are returned, reducing the risk of unexpected start-up.

Key features of these solutions include configurable interlocks that support a wide range of machine designs, space-efficient installation suitable for compact mounting areas, and the integration of all controls into a single unit, along with enhanced safety achieved through high-level coded modules and personnel keys.

Intec chose Fortress products because of their high reliability and adaptability, qualities that are essential in delivering machines capable of meeting international safety standards.

How Fortress can help

By using Fortress interlocks, AIC and Intec Robotics have reduced risks, ensuring that only the right person can access the right place at the right time. Since 1977, the company has delivered products for system integrators, OEMs, and manufacturers, spanning mechanical interlocks, tailored trapped key systems, and fully configurable networked solutions such as amGardpro and tGard with IO-Link Safety.

These solutions not only protect operators but also simplify installation, reduce wiring complexity, provide better diagnostics, and scale easily for expanding manufacturing lines. With a global presence and dedicated technical support, Fortress can help customers integrate interlocks in both legacy and modern automated production lines. 

fortress-safety.com