Machine Safety

In this article

» What is machine safety in industrial automation?
» What risks and hazards play a role in machine safety?
» How is machine safety applied in practice (Safety by Design)?
» Which components and systems are used for machine safety?
» Important standards and legislation: The new Machinery Regulation
» What is the difference between machine control and machine safety?
» Why is machine safety essential for industrial processes?
» How is machine safety maintained and evaluated?
» What are the latest trends and developments in machine safety?
» An Integrated Approach to Safe Industrial Installations
» Discover Ignition

What is machine safety in industrial automation?

In industry, machine safety refers to the combination of technical, organizational, and legal measures that ensure machines are designed, built, operated, and maintained safely. The goal of machine safety is to prevent personal injury, damage to machines and installations, and to ensure a safe working environment throughout the entire lifecycle of a machine.

Machine safety focuses on identifying, assessing, and controlling risks arising from the use of machines. These can include mechanical risks, electrical hazards, moving parts, or unexpected machine behavior.

What risks and hazards play a role in machine safety?

Within industrial environments, several types of risks are involved in machine safety. These risks often arise from the combination of mechanical movement, automation, and human interaction.

• Moving parts that may cause crushing or cutting hazards
• Unexpected machine startup during maintenance or malfunctions
• Electrical risks such as high voltage in control panels or drives
• Robots and automated systems operating within work areas
• Mechanical forces such as pressing, lifting, or cutting movements
• Human interaction with machines during operation or maintenance

The purpose of machine safety is to reduce these risks to an acceptable level through technical and organizational measures.

How is machine safety applied in practice (Safety by Design)?

Machine safety is implemented throughout the entire lifecycle of a machine: from design to maintenance and modifications. It is a powerful combination of engineering, control technology, and process management.

In practice, this process follows four consecutive steps:

1. Risk Assessment (The Foundation)

The process always starts with a thorough risk assessment. All potential machine hazards are identified and evaluated. Based on this analysis, the required measures to reduce risks are determined.

2. The Design Phase (Safety by Design)

During the design phase, the selected measures are translated into concrete technical solutions. This includes guarding hazardous zones, maintaining safe distances from moving parts, and mechanically limiting speed or force.

3. Realization & Control Systems

During implementation, physical safety components are installed to detect hazardous situations and safely stop the machine. In addition, specific safety functions are integrated into the control system.

⚠️ Important note regarding software: Not every software function automatically qualifies as a safety function. A function is only considered a true safety function when it runs on a dedicated safety PLC or certified safety system and is fully designed according to applicable standards.

4. Verification and Validation (The Real-World Test)

A crucial and independent step is verification and validation. Machine safety does not stop at the paper design or software code. In practice, physical testing must demonstrate that components such as emergency stops, light curtains, and interlocks respond exactly as intended in the risk assessment.

Which components and systems are used for machine safety?

Machine safety is achieved through a combination of hardware and software working together to ensure safe machine operation. These systems are designed to detect risks in time and intervene when necessary.

• Emergency stop buttons and safety switches
• Light curtains and safety scanners
• Safety PLCs and safety relays
• Safety zones and interlock systems
• Software-based safety functions within the control system

Together, these components form the technical foundation of machine safety and ensure machines stop in a controlled manner and can only restart when conditions are safe.

Important standards and legislation: The new Machinery Regulation

Machine safety is strictly regulated in Europe. Designers and machine builders must comply with stringent legislation and international standards.

🛑 Important transition: The industry is currently transitioning from the old Machinery Directive (2006/42/EC) to the new European Machinery Regulation (EU 2023/1230). Starting January 20, 2027, this regulation becomes mandatory. It introduces stricter requirements regarding cybersecurity of safety control systems and software updates (substantial modifications).

The three core international standards

Underneath European legislation lies a foundation of three key international standards that define how engineers must approach machine safety in practice:

• EN ISO 12100 – The foundation for risk assessment and risk reduction
• EN ISO 13849-1 – Focuses on the reliability of control systems (safety-related parts) and determining the required Performance Level (PL)
• IEC 62061 – Specifies requirements for functional safety based on SIL levels

Together, these standards form the international basis for the design and validation of machine safety systems.

What is the difference between machine control and machine safety?

Machine control and machine safety serve different purposes within an industrial installation. Control systems are focused on operating the production process, while machine safety focuses on preventing hazardous situations.

In practice, this means the control system ensures the machine functions properly, while machine safety always intervenes whenever an unsafe situation occurs. Within industrial automation, safety always has priority over production.

Why is machine safety essential for industrial processes?

Machine safety plays a critical role within industrial environments because it directly contributes to employee safety and the reliability of installations. It helps prevent accidents and minimize damage to machines and systems.

In addition, machine safety is essential for complying with regulations such as CE marking requirements. Well-designed machine safety also reduces downtime and creates a more stable production process by ensuring machines operate predictably and under control.

How is machine safety maintained and evaluated?

Machine safety is not a one-time activity but an ongoing process maintained throughout the entire lifecycle of a machine. This includes:

• Periodic inspections and testing of safety components
• Updating risk assessments when machine modifications are made
• Evaluating failures and incidents within the context of machine safety
• Adapting systems to new standards and technologies

What are the latest trends and developments in machine safety?

Within industrial automation, there is a clear shift taking place: machine safety is no longer purely mechanical but is becoming fully integrated with digitalization and data.

The four most important trends today:

1. Cybersecurity & Safe Software Updates

Due to the new Machinery Regulation (EU 2023/1230), cybersecurity has become a hard requirement within machine safety. Installations must be protected against external manipulation and cyber threats. In addition, the impact of software updates is now strictly regulated: updates may never unintentionally compromise an approved safety function.

2. Integrated Safety PLCs

Safety functions are increasingly becoming intelligent parts of digital control systems. Instead of standalone components, integrated systems such as advanced safety PLCs are becoming more common.

3. The Rise of Cobots (Collaborative Robots)

Humans and machines are increasingly working side by side within shared workspaces. Securing this close collaboration introduces continuously evolving and dynamic machine safety requirements.

4. Data Analysis and Predictive Maintenance

Data now plays a major role in monitoring machine behavior. Through real-time data analysis, abnormalities in safety components can be detected early, supporting predictive maintenance and helping prevent unplanned downtime.

In short: As modern industrial installations become more complex and connected, legal and technical requirements continue to increase. An integrated approach is the only way forward.

An Integrated Approach to Safe Industrial Installations

Machine safety is an essential part of industrial automation focused on the safe design, construction, and operation of machines. Through a combination of risk analysis, technical safeguards, and compliance with standards, machines can operate safely within industrial environments.

Machine safety is therefore not a separate discipline, but an integral part of the design and lifecycle of industrial installations.