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Complete safety solution for robotic palletizing cells

A light curtain, e-stop chains and gate locking on one safety block
August 10, 2026 by
Ričards Sleņģis
In a robotic palletizing cell the safety devices usually come from different makers and sit on different relay modules. When motion stops, the operator checks them one by one. The RSio block brings the light curtain, e-stops and gate switches into one system where every device stays individually visible.

6

Safety points on one block

32

Devices per ISD chain

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The problem

One cell, several separate safety systems

A palletizing cell runs a light curtain, e-stops along its sides, a gate switch and indication at the same time. When each device is wired separately, the reason for a stop is not visible in one place.

The reason for the stop is invisible

Buttons and switches wired in series look like one contact to the control system. The operator walks the cell and checks each device by hand.

 A relay and a cable for every device

The light curtain, gate switch and buttons often end up on different relay modules. The cabinet fills with modules and wiring runs in from every corner of the cell.

 Resetting happens at the cabinet

Once the safety device is reset, the system often has to be restarted from the control cabinet rather than where the operator is standing.

Solution

Complete safety coverage for a robotic palletizing cell, using hybrid I/O and In-Series Diagnostics on one RSio block.

The perimeter on the first input

The S4B safety light curtain guards the open side of the cell on one RSio safety input. The transmitter and receiver pair works up to 12 m apart at 30 mm resolution.

E-stops in one ISD chain

The buttons along the cell side are chained with M12 T-connectors and take one safety input. The ISD protocol runs over the same wiring as the OSSD signals, so each button stays individually identifiable.

The gate on the third input

The gate area has an e-stop, an SI-RF safety switch and an SI-GL42 locking switch that holds the gate shut until motion has stopped. The locking switch joins the chain through the SSA-ISD-TCA adapter.

Stop, indication and reset

A safety output drives the final switching device for the palletizer motion. Two ports configured as standard outputs drive the TL50 tower light and the K50 touch button. Once the device is reset, touching the K50 restores the input through the safety controller.
RSio · Paletizācijas šūna
Running cell guarded
SI 1 S4B gaismas aizkars · perimetrs OK
SI 2 Avārijas pogas · ISD ķēde, 4 ierīces OK
SI 3 Vārtu zona · SI-RF + SI-GL42 Locked
SO 1 Paletizētāja kustība Enabled
O 1 TL50 signāltornis un K50 poga Green
Ieejas6 Ierīces ķēdēlīdz 32 Izejas2 × 1 A Izejas reakcija5 ms
Statuss: normāls

Paātrināta demonstrācija - reālā sistēmā ierīču statuss ir redzams nepārtraukti vadības sistēmā.

What it changes in daily life

One block showing each device

The device is named immediately
ISD carries a status for every device in the chain, so the control system shows whether the light curtain, a specific button or the gate switch tripped.

One block for the entire cell
Six inputs and two outputs cover the perimeter, the buttons, the gate, the tower light and the reset button. Separate relay modules for each device are no longer needed.

Resetting occurs at the cell
The K50 touch button sits where the operator works. It shows the state by colour and restores the input on touch once the device has been reset.

The block is located by the equipment
The IP67 housing of 262 x 74 mm is made for machine mounting. Power and data run over M12 connections, and the cable runs from the corners of the cell get shorter.

Questions and answers

Frequently asked questions

No. Each RSio input can serve either one safety device directly or an ISD circuit. The light curtain occupies its input as a separate device.

With the SSA-ISD-TCA adapter. It converts the switch's two NC contacts into an ISD signal, and the switch appears in the circuit just like ISD devices.

No. It is connected to a port configured as a standard device and serves for indication and reset. The stop is performed by the safety output and safety devices.
One input can have up to 32 ISD devices, and one block can have up to 192 devices. Larger cells connect multiple blocks via Ethernet in series, star, or DLR ring.

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