Contrinex slimline YBES safety light curtains improve safety and productivity

Metal forming and assembly is an industry sector that face cost and competition challenges in the UK. Press shops for example face the challenge of maintaining the highest levels of operator safety while maximising machine utilisation and production throughput.

Whilst physical guarding systems like gates, screens and barriers provide effective protection, they can also restrict access, increase changeover times and create ergonomic challenges for operators working at the point of operation.

Non-contact safeguarding technologies, like Contrinex's safety light curtains overcome many of these limitations.

Safeguarding press operations without restricting productivity

Presses remain among the most heavily safeguarded machines within manufacturing facilities due to the significant hazards associated with moving tooling, pinch points and crushing zones. Historically, these risks have been controlled through the use of interlocked physical guards and safety fencing.

While effective, traditional guarding systems can negatively impact production efficiency. Operators frequently need to open and close access doors when loading components, removing finished parts or carrying out routine adjustments. In high-volume manufacturing environments, these seemingly small delays can accumulate into significant productivity losses over time.

Modern lean manufacturing practices demand greater flexibility. Production cells are expected to accommodate frequent product changes, smaller batch sizes and faster setup times, all while maintaining compliance with stringent machine safety regulations.

In many press shop environments, operators may be loading one machine while another completes its operating cycle. This requires unrestricted access to the working area combined with reliable safeguarding capable of immediately preventing hazardous movement when personnel enter the danger zone.

It is in these applications that Active Optoelectronic Protective Devices (AOPDs), more commonly known as machine safety light curtains, have become an increasingly attractive alternative to conventional physical barriers.

Engineered specifically for press applications

Contrinex's YBES Extended Slim safety light curtains have been developed to address the particular requirements of press shop and assembly machine applications.

Machine builders and system integrators commonly specify Type 4 (SIL3, Category 4, and PL e) safety light curtains with a 30 mm resolution for hand protection around hazardous machinery. The YBES range not only satisfies these requirements but provides a comprehensive certified safety solution suitable for applications requiring the highest levels of functional safety performance.

The system is certified to IEC 61496-1/2 Type 4, EN ISO 13849-1 Category 4, Performance Level e (PL e), IEC 61508 SIL 3, and TUV, CE and UL approvals. These certifications make the YBES range suitable for safeguarding applications where reliable personnel protection is critical.

The light curtain operates by creating a dense infrared protective field between a transmitter and receiver. If a hand, arm or object interrupts the protected zone, the integrated safety electronics immediately switch the OSSD (Output Signal Switching Device) outputs to their safe state, initiating machine stopping functions before personnel can reach the hazardous area.

Compact design maximises machine accessibility

A key advantage of the YBES Extended Slim range is its exceptionally compact 26 26 mm aluminium housing profile. Unlike bulky guarding systems that can obstruct operator access, the slimline design occupies minimal installation space, making it particularly suited to modern open-fronted machine designs.

For production personnel, this means easier access during component loading and unloading, tooling adjustments, machine cleaning, preventive maintenance activities and product changeovers. The compact design also enables machine builders to maximise the available working envelope without compromising operator safety.

An additional benefit is the elimination of blind zones. Through an internal optical architecture, the protective field extends fully to the edge of the device, ensuring comprehensive safeguarding even when mounted in corner or L-shaped configurations.

Increasing efficiency during changeovers

One of the most significant challenges for manufacturers today is reducing downtime associated with setup and product changeovers. Traditional guarding systems often require mechanical adjustments, alignment checks and maintenance interventions whenever tooling layouts are modified. This can consume valuable production time and increase engineering costs.

By replacing physical barriers with safety light curtains, operators gain unrestricted access to the machine while maintaining certified safety protection. This enables faster product transitions and supports the objectives of lean manufacturing programmes.

The YBES range further contributes to reduced downtime thanks to several built-in safety and monitoring functions, including: integrated External Device Monitoring (EDM); relay monitoring capability; manual or automatic restart interlock configuration; multiple beam coding options; permanent auto-control diagnostics; and optical synchronisation between transmitter and receiver.

These functions reduce the number of external safety components required, simplifying both installation and maintenance.

Bluetooth configuration simplifies commissioning

A distinguishing feature of the Contrinex YBES Extended Slim range is its built-in Bluetooth capability, enabling wireless configuration and diagnostics through the ContriApp.

Commissioning safety devices has traditionally required specialist software, dedicated programming hardware or proprietary configuration cables. In many factories, locating the correct tools or laptop software can add unnecessary delays to installation and maintenance tasks.

The ContriApp removes these obstacles by allowing engineers to use a standard smartphone or tablet for device configuration, alignment verification, diagnostic monitoring, fault identification, status monitoring and replacement unit commissioning. Integrated alignment LEDs provide immediate visual feedback during installation, helping engineers achieve optimum positioning quickly and accurately.

For maintenance teams, wireless access significantly reduces troubleshooting time and eliminates the need to carry specialist commissioning equipment.

The fact that the ContriApp is available free-of-charge from both the Apple App Store and Google Play Store means every maintenance engineer can have immediate access to configuration and diagnostic tools without additional licensing costs.

Built to withstand demanding manufacturing environments

Press shops are often subject to harsh operating conditions, including vibration, mechanical shock, dust and temperature variations. To ensure long-term reliability, the YBES Extended Slim range incorporates rugged aluminium extrusion housings, shatter-resistant PMMA optics, IP65/IP67 environmental protection, operating temperatures from 0degC to +55degC, and high resistance to industrial shock and vibration.

The range offers protective heights from 170 mm to 1610 mm and operating distances of up to 5 metres, allowing machine designers to safeguard a wide variety of machinery and access points.

Connection to machine control systems is achieved through industry-standard M12 connectivity, ensuring straightforward integration into existing safety relays, safety controllers and PLC-based safety architectures.

As manufacturers continue to pursue greater efficiency and flexibility, intelligent safeguarding technologies such as the Contrinex YBES Extended Slim range demonstrate that safety systems can do much more than protect personnel. They can also play a valuable role in improving productivity, reducing operational costs and supporting the wider goals of smart manufacturing and factory automation.