Access guarding with dynamic format adaptation

The increasing automation of machinery and systems places growing demands on the necessary safety concepts. Classic concepts, such as muting, are often pushed to their limits here. Our innovative safety solutions guarantee gapless safety, efficient material flow and high availability of your system, even with automated processes.

One challenge with access guarding on conveyor lines is the handling of different sizes and positions of the transported goods. While it is possible to fi nd integrated safety concepts for situations in which the size of the goods remains identical – for example, on the basis of muting functions – gaps in safety quickly arise if the width of the goods, the positioning of the goods on the pallet or the positioning of the pallet on the conveyor belt changes. This applies above all for the area alongside the transported goods. With its superior safety concept, the Leuze safety solution with dynamic format adaptation offers the right solution for these applications.


Pallets are automatically fed in and out by a conveyor belt. Access guarding should permit the transport of goods with changing width as well as with different positioning on the pallet and simultaneously prevent persons from running alongside.

Access guarding takes place via two vertically oriented safety laser scanners. Measuring sensors determine the width and position of the goods and send this information to the Leuze safety system. This appropriately adapts the protective field for passage of the goods.

Operating principle:
Two safety laser scanners produce a vertical protective field. Installed in front of the protective field on both sides next to the conveyor line are optical distance sensors that detect the width of the goods and their position on the conveyor line. The safety system uses this information to release an appropriate window in the protective field through which the goods can be transported interruption-free. Access remains safeguarded alongside the goods. After the goods have passed through the opened protective field window, the protective field is again reset to its original, closed state. The entire process is monitored for safety.

Advantages for you

  • Continuous monitoring of the entire access area
  • Gapless safety during the transport cycles
  • High reliability and availability
  • Low service costs
  • Optimum protection against manipulation
  • Easily retrofittable

System components and safety parameters

  Safety sensor: RSL 400 safety laser scanner
Measuring sensors: ODS optical distance sensors
System control: MSI 400 safety control
Leuze safety program
PL d in accordance with ISO 13849-1, SILCL 2 in accordance with IEC 62061
2-channel safety output


Safety Solutions - Flyer (PDF, ~0.8 MB)
Access guarding with dynamic format adaptation