Why Hard-Stop?
Traditional safety devices protect fixed zones. But what about the scenarios they can't see?
hand and finger injuries per year in US manufacturing
Source: BLS
average cost per machine-related injury incident
Source: NSC
of machine injuries occur during non-routine tasks where guards are bypassed
Source: OSHA
What Triggers a Hard-Stop?
Visionify detects these safety events in real-time and signals your PLC to halt machinery immediately
Hands in Restricted Area
Detects when a worker's hands enter a machine's danger zone, such as near a press brake, punch press, or conveyor pinch point, and immediately signals the PLC to halt the machine.
Example:
A press brake operator reaches past the light curtain to adjust material. Visionify detects the hand intrusion and triggers an immediate machine stop before the ram descends.
Person in Restricted Zone
Triggers a hard-stop when anyone enters a defined danger zone around robotic cells, automated machinery, or hazardous process areas.
Example:
A maintenance worker steps into a robotic welding cell without lockout. The system detects the intrusion and stops all robotic movement instantly.
Missing Mandatory PPE
Stops machinery when a worker is detected operating equipment without required PPE: no gloves near chemical dispensers, no face shield at grinding stations, no safety glasses at cutting machines.
Example:
An operator approaches a chemical mixing station without gloves. The system prevents the dispenser from activating until proper PPE is detected.
Unsafe Posture or Behavior
Detects dangerous body positions or behaviors, such as reaching into running machinery, climbing on equipment, or bypassing safety guards, and stops the machine before injury occurs.
Example:
A worker leans into a CNC machine enclosure while the spindle is running. Visionify detects the unsafe posture and triggers an immediate stop.
How It Works
From AI detection to machine shutdown in under 500 milliseconds
AI Detects the Safety Event
Visionify's Edge AI continuously analyzes every camera feed on the OT network, flagging hands in danger zones, missing PPE, unauthorized personnel, and unsafe behaviors the moment they occur.
- Sub-second, frame-by-frame inference on-prem
- 30+ validated AI-powered safety events out of the box
- No cloud dependency — runs on your Edge Server
Signal Sent to the PLC
On a confirmed event, Visionify issues a digital command to your PLC over standard industrial protocols — with continuous heartbeat monitoring so communication health is never in question.
- EtherNet/IP, PROFINET, Modbus TCP, OPC UA
- Bi-directional heartbeat with the PLC
- Typically under 100 ms across the OT VLAN
Machine Stops Immediately
Your PLC executes its pre-programmed safety routine — halting the machine, retracting actuators, or disabling outputs — based on logic your controls engineer already trusts.
- Under 500 ms end-to-end from detection to stop
- Additive to existing light curtains and e-stops
- Your PLC remains the authority on safety logic
Event Logged & Alert Sent
Every hard-stop is captured end-to-end: video clip, timestamp, trigger reason, and camera context — pushed instantly to supervisors and archived for EHS reporting.
- Video evidence saved with every event
- Real-time alerts via dashboard, email, or SMS
- Full audit trail for safety audits & root cause
Not Ready for a Full Hard-Stop?
Some teams prefer a softer intervention — a stack light or audible alarm that prompts workers to self-correct without halting production. The same Visionify detections drive industrial stack lights and buzzers, with zero changes to your PLC program.
- Drive red / amber / green stack lights + buzzers
- Powered by the same AI detections, different output
- Zero changes to your existing PLC program
Not Ready for a Full Hard-Stop? Try Audio-Visual Alerts
Some customers prefer a lighter-touch response: a stack light or audible alarm at the point of risk that prompts workers to self-correct—without halting production. Visionify drives industrial stack lights (red / amber / green) and buzzers directly from the same AI detections that power hard-stop.
Visible at the Point of Risk
Universally understood red/amber/green signals alert workers directly on the floor—no screen required.
Audible Alerts
Optional buzzer integration ensures alerts reach workers in noisy environments or when attention is focused on a task.
Non-Disruptive to Production
Prompt corrective action without halting machinery—ideal when a soft intervention is preferred over a full hard-stop.
OT-Network Native
Runs entirely on the local OT VLAN with HTTP/VAPIX. No cloud dependency, no internet required for alerts to fire.
How the Audio-Visual Integration Works
Visionify Edge Server → HTTP/VAPIX command → Axis A9210 Network I/O relay → 24V DC stack light segment energizes. Events auto-clear when the violation resolves.
Supported Safety Events
Any Visionify detection can drive the stack light. Common configurations validated in industrial deployments:
Full Audio-Visual Integration Guide
Wiring diagrams, VAPIX API reference, multi-station expansion, and troubleshooting.
Supported PLCs & Protocols
Works with all major industrial control platforms through standard protocols
Allen-Bradley (Rockwell)
ControlLogix, CompactLogix, Micro800
Siemens
S7-1200, S7-1500, S7-300/400
Mitsubishi
MELSEC iQ-R, iQ-F, Q Series
Omron
NJ/NX Series, CJ2, CP2
Schneider Electric
Modicon M340, M580, M251
Beckhoff
CX Series, C60xx
Resources
Everything you need to integrate Visionify hard-stop with your PLC
PLC Configuration Guide
PDF · 24 pagesStep-by-step guide to configuring Visionify hard-stop triggers, PLC communication setup, safety zone definitions, and event-to-action mapping.
Download PDFPLC Template Application
Open Source · MIT LicenseOpen-source Python application that receives Visionify webhook events and translates them into PLC commands. Supports multiple protocols out of the box:
Industries
Hard-Stop integration is used across industries where machinery poses injury risk
Manufacturing
- Press brakes & stamping
- CNC machining centers
- Assembly line robotics
- Conveyor systems
Automotive
- Welding cells
- Paint shop robotics
- Body-in-white assembly
- Parts stamping
Food & Beverage
- Mixing & blending equipment
- Packaging machinery
- Slicing & cutting lines
- Palletizing robots
Metals & Mining
- Rolling mills
- Foundry equipment
- Cutting & grinding
- Material handling
Pharmaceuticals
- Tablet presses
- Filling lines
- Packaging equipment
- Clean room machinery
Logistics & Warehousing
- Automated sortation
- Palletizing systems
- Conveyor networks
- Robotic pick stations
Frequently Asked Questions
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