As Chinese manufacturing continues to upgrade toward higher-quality production, the home appliance industry has developed a comprehensive supply chain covering a wide range of product categories. Flexible manufacturing and mixed-model production have become increasingly common to meet diverse consumer demands. However, manufacturing processes also involve significant safety risks, including mechanical injuries and unauthorized personnel entering hazardous areas, which can directly affect worker safety and production continuity.
To address these challenges, this industrial safety protection installation solution has been developed based on the specific characteristics of home appliance manufacturing processes. It integrates safety light curtains, safety mats, LiDAR, and other safety devices, with “positioning, graded protection, and coordinated interaction” as its core principles. Based on a multi-level protection logic covering points, lines, areas, and three-dimensional spaces, the solution establishes a comprehensive safety protection system that combines safety control, equipment coordination, and redundant protection, helping manufacturers strengthen workplace safety while maintaining production efficiency.
In core metal component processing operations, stamping equipment, including CNC punching machines and hydraulic presses, presents risks of crushing and shearing when workers accidentally enter the die area during high-speed stamping or mold closing operations. Frequent equipment start-stop cycles can also increase the risk of accidents caused by operational errors.
To address these risks, the solution provides two primary protection options:
1. Safety Light Curtain Protection
A continuous protective light curtain is created between the transmitter and receiver to cover the hazardous area of the stamping equipment. When a person or foreign object interrupts the light curtain, the equipment immediately stops. Once the person leaves the hazardous area, the system can automatically reset, providing real-time, non-contact safety protection.
2. Laser Sensor Protection
A customizable three-dimensional protection zone can be preset around the equipment. When a person is detected entering the hazardous area, the system immediately issues a stop command.
Compared with safety light curtains, the key advantages of laser sensors include greater flexibility in protection distance and the ability to position the protection zone closer to the hazardous core area. The shape of the protected area can also be edited according to the layout of the stamping dies, making it suitable for complex operating environments.
During auxiliary assembly operations, robotic arms, including collaborative robots and assembly robots, perform dynamic tasks such as picking, screw fastening, and component assembly. Their movement covers a wide area and they can respond extremely quickly. Collisions or crushing incidents involving personnel can therefore create significant safety risks.
This challenge becomes even more important in mixed-model production, where frequent product changes require highly flexible safety protection.
To address these requirements, the solution establishes a three-level coordinated protection system combining safety light curtains, safety mats, and LiDAR:
Safety Light Curtain: Installed at the entrance of the equipment safety fence to create a protective barrier and monitor personnel entering or leaving the area in real time.
Safety Mat: Installed around the robotic arm's operating area to provide floor-level protection through pressure sensing, making it suitable for workstations where personnel frequently move in and out.
LiDAR: Installed at floor level to create a protective perimeter and expand the overall protection coverage.
These three protection layers work progressively and in coordination. They can quickly trigger equipment shutdown when personnel approach or accidentally enter hazardous areas while also accommodating the dynamic operating requirements of flexible assembly. This provides dual protection for both workplace safety and production efficiency.
During plastic component processing, injection molding machines present risks such as crushing and burns when personnel accidentally enter the mold-closing area or molten-material injection zone during mold closing, injection, ejection, and part removal operations.
The process must also accommodate collaborative scenarios involving robotic part removal from inside the mold and manual assistance.
The solution uses the Moncee Yinwei MZS-01 3D photosensitive sensor to establish an intelligent protection system. Its key advantage is its ability to perform scene recognition and protection-zone determination.
When the robotic arm is operating inside the mold for part removal, material feeding, or other tasks, the Moncee Yinwei MZS-01 3D photosensitive sensor does not interfere with normal production. Once the robotic arm exits the mold and enters the predefined protection area, if personnel are still detected within the hazardous zone, the system immediately triggers a safety stop of the robotic arm.
Normal operation automatically resumes once personnel have completely left the hazardous area. This approach provides reliable safety protection while maintaining the continuity and flexibility of injection molding operations.
In packaging and logistics operations, equipment such as stretch wrapping machines and palletizing robots continuously performs tasks including material wrapping, packaging, and finished-product stacking.
These operating areas typically experience significant personnel movement and may involve potential risks such as robotic arm collisions and falling materials. These risks are particularly relevant in areas where manual material replenishment and finished-product handling take place simultaneously.
In such applications, safety protection must balance area monitoring with production continuity.
The solution uses LiDAR as the core protection device. By defining a customized scanning range around the equipment, it creates a non-contact protective zone.
When LiDAR detects a person entering the predefined protection area, it can trigger either an equipment alarm or a shutdown command according to the requirements of the specific application. Once the person leaves the protected area, the equipment can automatically resume operation.
The following are Moncee Sensor's safety mat, LiDAR, safety light curtain, and laser sensor products.
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