As Industry 4.0 and smart manufacturing approaches continue to change the manufacturing landscape, most discussions focus on automation, data analytics and process efficiency. However, one area that is frequently overlooked is how smart technology and artificial intelligence (AI) can improve workplace safety, especially for small and medium sized manufacturers (SMMs). Thanks to advancements in sensors, AI, and related connected systems, and the reduced cost of implementing these technologies, it is now possible to predict, detect, and even prevent common workplace hazards in ways that were impossible or unaffordable before.
How Sensors are Changing the Game
Sensors provide the foundation for a safer, smarter workplace. These compact, often low-cost devices can now detect everything from proximity and vibration to temperature, gas levels, posture, and fatigue.
Proximity and motion sensors can prevent a worker from walking into an unsafe environment by slowing down equipment or even bringing it to a stop. The integration of force sensors is part of what adds the “collaborative” to “collaborative robots” (Cobots). By utilizing sensors, the cobot can detect when an unexpected amount of force is applied and temporarily halt operations, which can make the difference between an operator being injured or not.
Sensor equipment can also help monitor the health of our equipment, which can improve safety. Vibration, temperature, and acoustic sensors often can detect signs of wear or failure before a catastrophic breakdown occurs, such as an operator injury due to tool breakage.
Even if the sensors are not directly integrated into the equipment by the manufacturer, they are often added to increase efficiency. “Light Curtains,” which utilize an infrared beam, are often used to provide a virtual barrier between operators and equipment. If anything—like a hand, arm, or tool—breaks the beam, the machine immediately slows or stops its motion to prevent injury.
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