Radar safety systems

Industrial Safety Radar Systems for Reliable 3D Zone Monitoring

The Inxpect industrial radar safety system provides reliable human detection and restart prevention in environments where optical safeguarding devices cannot operate consistently. The FMCW radar technology is immune to dust, dirt, mist, sparks, vibration and changing light conditions, and is certified for applications up to PL d (EN ISO 13849-1) and SIL 2 (EN/IEC 62061).

Why choose radar instead of optical safety systems?

In areas with dust, debris, splashes, vapour, sparks or reflections, conventional light curtains and laser scanners are prone to false trips or signal loss. Inxpect’s Frequency Modulated Continuous Wave (FMCW) radar operates reliably under these conditions, ensuring accurate detection of people and movement even when optical systems fail.

What is a 3D radar safety system?

A 3D radar safeguarding system is an advanced machine-safety technology that uses radar frequencies to detect human presence and movement within a three-dimensional volume. Unlike optical systems that monitor a line or a plane, a 3D radar system generates a full detection volume.

This enables highly accurate monitoring of an operator’s position—whether inside a hazardous zone, at the boundary, or leaving the area. As a result, 3D radar sensors are ideal for:

• restart prevention
• presence detection in restricted areas
• entry / intrusion detection

The Inxpect radar safety architecture supports configurable fields, discrimination between people and objects, and flexible zone definition through the Inxpect Safety Application. It provides high safety performance without impacting productivity, even in demanding environments.

How does an industrial radar safety system operate?

The system consists of a central safety controller and up to six radar sensors. Together they create a 3D detection volume in which human presence is reliably identified. Upon detection, the controller immediately switches the OSSD safety outputs to a safe state, preventing machine restart or motion. This ensures safe maintenance access, safe intervention and controlled stop states.

Advanced detection fields for every application

Inxpect radar sensors support several configurable detection fields:

• Symmetric Field of View: equal coverage on both sides for general zone safeguarding.
• Asymmetric Field of View: prioritised coverage near walls or obstructions.
• Corridor Field of View: optimised for narrow passages such as aisles or transport tunnels.

Detection distances can be configured from 4 to 9 metres, with horizontal spans between 10° and 100° depending on the sensor. The S101 model provides fixed wide- or narrow-angle detection options.

Intelligent configuration using the Inxpect Safety Application

The free Inxpect Safety Application enables precise configuration and validation:

• Visualise zones and sensor placement with CAD-based layout tools.
• Adjust I/O configuration, sensitivity, filtering and response time.
• Generate validation reports and documentation for CE compliance.

The software runs on Windows and macOS and is essential for commissioning, diagnostics and conformity assessment.

Advantages of radar-based zone monitoring

• Completely immune to dust, humidity, steam, smoke and temperature fluctuations.
• Reliable human detection—no nuisance stops from small objects or debris.
• Heavy-duty IP66/IP67 housing for harsh environments.
• Zone coverage up to 4 m × 15 m using six sensors on a single controller.
• Fast response suitable for AGV routes, robot cells and high-speed axes.

Typical applications of Inxpect radar safety

• Restart prevention in robotic cells
• Human detection around overhead cranes
• Entry detection in automated loading/unloading stations
• Access monitoring along AGV and transfer-conveyor paths

Compatibility and installation

The system integrates using standard 8-pin M12 connectors and supports wall, floor or ceiling mounting. The modular design allows easy installation in both new and existing machines—without the need to modify optical safeguarding devices or install additional light curtains.

Maximum safety without compromising productivity

For environments where optical safety systems struggle, Inxpect delivers a stable, high-performance alternative. With PL d and SIL 2 certification, the radar system provides a reliable safety function without reducing machine uptime or process continuity.

Support and technical guidance

Our machine-safety engineers can support you with configuration, system design and integration of the correct radar safety solution. Contact us for technical advice, product selection or assistance with CE documentation and implementation.