OMRON: Integrated Safety – One View, Total Control & Zero Compromise
October 1, 2025
Integrated Safety: Safety & Automation in One Seamless System from the Start
Integrated Safety is a fundamental approach to the design of machines and production lines, where safety features are built in from the start rather than added later. Integrated Safety combines safety and automation in a single control system. A safety PLC or intelligent controller manages both automation and safety using software-based safety logic.
This ensures that every part of a machine’s operation is considered for safety and included in the standard control system data. By incorporating safety from the beginning, you can ensure the highest level of safety for your people and equipment, while also gaining valuable data to help quickly assess and prevent future problems.
What Is Basic (Non-Integrated) Safety in Automation?
Basic safety involves an input device, a logic device, and an output device. This configuration can be abbreviated as ILO for “Input, Logic, Output.”
- Input Devices (like light curtains, scanners, door interlocks, safety mats, or E-stops) detect when a person enters a hazardous area or manually trigger a stop.
- Logic Devices process the signal to decide if action is needed to cut power or remove hazardous energy in the case of emergency stop circuits or keep motion on reduced speed for protective (Safeguard)circuits.
- Output Devices (like contactors or clutch brakes) then act to eliminate the hazard—either by disconnecting power or physically stopping motion.
The main difference from Integrated Safety is that each part is usually a separate, hardwired device, forming a full standalone safety system. And this linkage between the safety signals and the standard parts should be taken in consideration.
When to Choose Integrated Safety
Integrated Safety is ideal for more complex and scalable machines with many safety I/O points or where advanced safety functions and diagnostics are needed. Systems using safety PLCs merge all safety and control signals into one intelligent controller—enabling:
- Greater flexibility and scalability
- Easier system updates and modifications
- Seamless communication between safety and standard control
- Mid and Long-term cost savings and performance gains
For simpler machines with basic safety needs, non-integrated systems using safety relays can still be effective. They’re often more familiar to technicians and cost-efficient for small-scale applications. However, as machine complexity increases, these systems become harder to adapt, more wiring-intensive, and less efficient.
Key Decision Factors Include:
- Number of safety I/O points
- System complexity
- Required integration with control logic
Choosing the right approach ensures optimal safety, performance, and maintainability.
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Integrated Safety Requires One Software for Automation & Safety: Sysmac Studio
OMRON’s SYSMAC Studio is the all-in-one engineering tool for designing, programming and troubleshooting automation systems, from basic machines to complex lines with integrated safety.
Why It Matters:
With Sysmac Studio, you can manage Omron’s entire Input–Logic–Output + Safety & Robotics (ILO+SR) portfolio through a single software environment—boosting design efficiency, improving safety, and reducing engineering time.
- Less hardware, fewer errors
- Faster setup & maintenance
- Integrated safety to meet PL e / SIL 3 standards
Together with its partner network, OMRON provides safety components and expertise to support integrated safety, from creation to commissioning.
Key Capabilities:
- Unified Programming Environment: Configure and program both standard and safety controllers, using ladder logic, structured text, and IEC 61131-3 compliant function blocks.
- Seamless Network & I/O Setup: Easily build networks (e.g. EtherCAT, FSoE) and add I/O modules, including safety I/O, with drag-and-drop configuration reducing wiring complexity.
- PLCopen Safety: Sysmac Studio includes built-in function blocks and supports PLCopen Safety compatible function blocks and instructions to speed up development.
- System Integration: Combine PLCs, HMIs, vision systems, drives, and safety devices within one platform for better coordination and easier scaling.
- Simulation & Testing: Test programs virtually before deployment to minimize commissioning time and catch issues early and also applies to the Safety logic.
- Real-Time Diagnostics: Monitor all devices, I/O, and safety systems live. Get instant insights for faster troubleshooting and predictive maintenance.
- Integrated Safety Programming: Develop certified safety logic using pre-built function blocks for E-stops, guard doors, and more—fully integrated within the same controller and software, with full diagnostics shared anywhere.
Experience the High-Performance Safety & Efficiency with OMRON’s Integrated Automation Solutions
For more information HERE
