Power & Control System Engineering
Category 3 Safe Inspection Device Retrofit
A third-party pneumatic inspection device retrofit to Category 3 safety, protecting the hands that work it every cycle.
CLIENT
INDUSTRY
SOLUTION
DURATION
The Challenge
The customer’s inspection device was a third-party, purely mechanical and pneumatic machine. Team members load molded products, clamp and inspect them with their hands right at the lifter and clamp cylinders, every cycle, all shift. That is a high-exposure position for pinch, crush and finger injuries, and the device’s simple air controls did not meet the plant’s required safety level. The customer needed it brought up to Category 3 without replacing equipment that already did its job.
Key Requirements
- Bring the device to Category 3 safety performance
- Keep team members’ hands clear during every powered motion
- Hold the load safely on loss of air or power
- Lockable air shutoff and E-stop
- Guard cylinder pinch points
- Retrofit the existing third-party device, no replacement
- Simple, clear operator controls
The ICR Solution
ICR completed the inspection device retrofit with a safety-rated control system. A safety PLC now monitors every input and output, and motion only happens while the team member holds two Banner safety touch buttons, one for each hand, so both hands are clear of the lifter and clamp. The air side is fail-safe by design: an SMC safety master valve passes air only while the two-hand control is active, exhaust-center and pilot check valves plus Schunk pressure-maintaining valves hold the load if air or power is lost, and pressure switches confirm system pressure. ICR added a lockable shutoff, E-stop and master and reset controls, limit switches, button guards and a perforated guard that fully encloses the lifter cylinder, all documented with a risk assessment and residual pressure map. The Keyence SR-2000 code reader ICR integrated on an earlier project stays in service.
Equipment & Technology
- Safety PLC with safety I/O
- Banner STB safety touch buttons (two-hand control)
- SMC safety master supply valve
- Exhaust-center and pilot check valves
- Schunk pressure-maintaining valves
- SMC pressure switches and lockout FRL
- Omron limit switches
- E-stop, master and reset station
- ICR-fabricated lifter cylinder guard and button guards
- Keyence SR-2000 code reader (from a prior ICR integration)
Scope of Work
- Risk Assessment
- Safety Circuit Design
- Mechanical Design
- Pneumatic Design
- Fabrication
- Panel Build
- Safety PLC Programming
- Retrofit Installation
- Validation and Documentation
Results
The inspection device now meets Category 3 safety requirements. Team members’ hands are guaranteed clear of the lifter and clamp during every powered motion, the fail-safe air circuit holds the load if air or power drops, and pinch points are guarded. The customer kept equipment that already worked, met its safety standard, and protected the people whose hands are on it all shift.