It is commonplace for safety systems to be operated independently from other systems. As facilities grow smarter and more automated, safety systems are at risk of being left behind. Safety equipment specialist EUCHNER explains why it is so crucial that safety systems evolve.
As manufacturing, fulfilment, and logistics facilities become smarter and more autonomous, safety systems must evolve too. Increasingly, that means moving beyond hardwired, standalone devices to intelligent, networked systems that integrate directly into automation architectures.
At the centre of this evolution are guard locking devices like EUCHNER’s MGB2 Modular, which now offer direct communication with Safety PLCs over industrial Ethernet. Combined with access control systems like the CKS2 RFID key system, these devices enable flexible, scalable safety solutions that meet the demands of modern production environments.
From isolation to integration
Traditionally, safety functions like guard locking, interlocks, emergency stops and access control operated independently from the main control system, hardwired to central safety relays. While reliable, this model can be limiting in dynamic facilities where production lines change frequently and uptime is critical.
Hardwired safety adds wiring complexity, increases panel space and limits diagnostics, often turning safety into something that must be worked around rather than built in.
That’s changing. Ethernet-based safety networks such as PROFIsafe over PROFINET, CIP Safety over EtherNet/IP, and FSoE over EtherCAT allow guard locking devices to communicate with the control system over the same network. This delivers a fully integrated, safety-certified communication channel with advanced functionality, real-time diagnostics, and scalability.
Devices like the MGB2 Modular benefit from simplified installation, reduced panel space and software-based commissioning. Real-time diagnostics mean faults can be located quickly, without time-consuming manual checks. These protocols support decentralised architectures, enabling devices to be repositioned or reconfigured without major rewiring. Moreover, they meet rigorous safety standards BS EN ISO 13849-1 and BS EN IEC 62061 to achieve the highest performance levels in machinery safety of Ple and SIL3.
MGB2: built for the networked era
The MGB2 Modular is a perfect example of connected safety in action. Designed for demanding applications in manufacturing and logistics, it combines guard locking, control functions and diagnostics in a single device.
Its standout feature is native support for Ethernet-based safety, enabling direct integration with all major safety networks and seamless communication with Safety PLCs. There’s no need to route individual safety contacts to a central cabinet. All status, diagnostics, and access requests are transmitted via the network, often viewable on existing HMI or SCADA systems.
This integration simplifies engineering and enhances visibility. Expansion modules allow additional components like emergency stops, selector switches, or signal lights to be connected and addressed over the network, reducing the need for separate control components and making operator interfaces more intuitive.
Smarter access with the CKS2
Access control isn’t just about compliance, it’s about enabling safe, efficient interventions. In facilities where temporary access is often needed (e.g., to clear a jam or make quick adjustments), traditional mechanical key systems can be restrictive.
The CKS2 RFID key system provides a modern alternative. It replaces mechanical keys with coded RFID ones connected directly to the safety network, streamlining access control without compromising safety.
A typical workflow involves removing a key from an MGB2 or control station to gain access to a safeguarded area. In some cases, the key is inserted into a second reader inside the zone to enable safe functions like jog mode or diagnostics. Only when all keys are returned can the system restart.
This electronic approach removes the physical limitations of mechanical systems while maintaining strict control. Integrated with the safety PLC, access can be logged, restricted, or granted dynamically, improving safety, reducing downtime, and cutting administrative burden.
Designed for evolving environments
Facilities are constantly evolving new lines, reconfigured layouts, and increasing automation. In such environments, adaptability is essential.
With devices like the MGB2 and CKS2 connected to the network, changes become easier to implement. New modules can be added with minimal reconfiguration, diagnostics can be performed remotely, and safety functions are monitored in sync with the rest of the automation system.
This also opens the door to predictive maintenance. With data flowing from each safety device, wear, misalignment, or unusual usage patterns can be detected early, avoiding unplanned shutdowns and improving reliability.
One device, global flexibility
For global operations, standardising on a single platform is a strategic win. The MGB2 Modular supports all major safety protocols, allowing the same hardware to be deployed across facilities regardless of the PLC vendor.
This simplifies sourcing, reduces engineering effort, and future-proofs safety investments. As operations expand, the same safety devices can move with them, supporting scalable, consistent safety across regions.
Connected safety is better safety
Automation is about more than speed and efficiency, it’s also about safety. That safety must be just as smart and connected as the systems it protects.
By choosing Ethernet-connected devices like the MGB2 Modular and CKS2, manufacturers gain not just compliance, but control, transparency and agility.
Whether in a smart warehouse, an automotive line, or high-speed packaging plant, connected safety is becoming the new standard, enabling a safer, smarter and more resilient future.
For further information, visit EUCHNER’s website.
