Correcting Light Curtain Placement for Optimal Safety

The client had recently installed light curtains as part of their machine safeguarding system. Confident in the setup, they presumed the installation met all required safety standards. However, no formal verification had been performed to ensure the light curtains were positioned at the correct distances for optimal protection.

Challenge

Light curtains are critical safety devices designed to protect operators from hazardous machine areas. If installed incorrectly, they may fail to stop machinery in time, creating significant safety risks. The client’s main concern was to confirm that their light curtains were effectively safeguarding personnel.

Our Role & Implementation

Initial Observation

The existing placement of the light curtains was documented, including distances from the hazardous areas.

Testing & Verification

Using industry-standard measurement tools and test procedures, the light curtains were evaluated to determine if they would effectively detect an operator’s presence.

Calculation of Safe Distances

Based on the type of light curtain and machine stopping time, calculations were performed to determine the correct safety distances according to relevant safety standards (e.g., ISO 13855).

Findings

The testing revealed that the initial installation did not provide adequate safety coverage. The light curtains were placed too close to the hazardous area, which could have delayed the machine’s stopping response in the event of intrusion.

Relocation

The light curtains were relocated and repositioned to the calculated optimal distances to ensure they would stop the machine safely if triggered.

Outcome

Enhanced Safety: Operators are now fully protected by correctly positioned light curtains.
Compliance: Installation now meets industry safety standards and PUWER.
Peace of Mind: The client gained confidence that their safeguarding system is effective and reliable.

Conclusion

Assumptions about equipment installation can lead to critical safety gaps.
Testing and verification are essential for safety-critical devices like light curtains.
Accurate calculations and professional repositioning ensure both compliance and operational safety.

This case underscores the importance of validating safety systems. By testing the light curtains and repositioning them correctly, the client achieved full protection for operators while ensuring compliance with safety regulations.

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