SICK: Easily Integrated Safety – Modern Controller & Safety Solutions for Efficient, Cost-Effective Machine Building
June 16, 2026
Integrated Safety Technology: Modern Controller & Safety Solutions from SICK
Safety technology in machine building is much more than just meeting stringent standards – it is a strategic success factor. Modern safety systems not only protect people but make responsibility visible, stabilize processes and increase profitability. It is precisely at this interface that protection of people and system availability meet: Where functional safety creates trust: smooth processes, high availability and long-term competitive advantages follow.
At the same time, the requirements on simple, flexible and easy to integrate solutions are growing. Machine building companies are faced with the challenge every day of balancing safety, efficiency and flexibility. Maintenance and service require consistent, clearly diagnosable control platforms. Safety representatives ensure compliance conformity, while engineering teams need to design processes to be more efficient and safer. Added to this is the expectation of fast project planning, short commissioning times and a modular, scalable integration – all supported by rugged and cost-effective technologies.
In light of this, the demand for safety technology that not only provides reliable protection but is also easy to select, configure and operate is growing. Machine safety thus becomes a key success principle: clear product structures, comprehensible services, easy installation and intuitive operation that reduces downtimes and increases productivity.
Safety as Key Success Principle: From Planning to Operation
As an experienced safety partner, SICK brings exactly these requirements together in a consistent portfolio: compact safety controllers, safe series connections and space-saving safety relays that fulfill high safety standards while at the same time enabling quick, uncomplicated integration. With Flexi Compact, Flexi Loop and ReLy, SICK demonstrates how safety and efficiency can be seamlessly combined – from planning to commissioning to ongoing operation.
You not only make decisions on the quality and reliability of machine tools, presses, assembly and handlings systems or conveyor systems, but also shape the maintenance and service processes, the planning of safety assessments, and the smooth operation of automated production steps. To reliably protect humans and machines, you need to meet stringent safety requirements – right through to SIL3 and PL e – while at the same time ensuring that new safety systems can be quickly integrated into existing systems.
This is precisely where the demand for user-friendly, flexible solutions that increase productivity and minimize downtime arises. As an experienced safety partner, SICK offers a portfolio of safety solutions for machine building that meet the high requirements of a wide variety of applications.
Trends in the Automation of Mobile Machines – Guide for Download HERE
Flexi Compact: Modular Safety Controller for Fast Integration
Flexi Compact was developed as a compact safety controller for the requirements in machine building. The software-based configuration, high safety standards and modular architecture provide the foundation for tailor-made safety functions – from door and access protection to emergency stop concepts. Depending on the application, the system can be extended with I/O modules and gateways and easily integrated into existing networks via the integrated Ethernet port. Communication occurs over the integrated RJ45 interface via Modbus TCP.
The advantage to the business is immediately apparent: Thanks to fast commissioning and flexible adaptation, companies ensure the availability of their systems, optimize production processes, reduce costs and in so doing develop high-quality, safe machines – a solid foundation for future-proof machine concepts and competitive advantages.
Flexi Loop: Safe Series Connection with Clear Diagnostics
With Flexi Loop, a safe series connection is available that can connect up to 32 safety sensors up to PL e via only a single output and two inputs. Up to 16 Flexi Loop chains can be integrated per Flexi Compact station, which significantly reduces the wiring effort. Seamless diagnostic functions in the software and device ensure maximum transparency regarding the current safety status.
Protective field interruptions, switch-offs or safety-relevant states are identified unambiguously and can be displayed on the machine HMI. This enables operators to quickly recognize the causes and respond in a situation-appropriate manner – a clear advantage for stable and efficient operation of systems.
ReLy: Space-Saving Safety Relay for High Availability
The ReLy Safety Relay supplements the platform with a consistent user-friendly housing design and narrow widths starting at 18 mm, which saves space in the control cabinet and makes installation easier. Short response times of under 12 ms allow reduced safety distances and thus more compact machine layouts. Supplemented by comprehensive diagnostic options, Rely pays off with a higher machine availability – during machine operation and in series applications.
SICK Safety Controllers Flexi Compact
SICK Safe Series Connection Flexi Loop
SICK Safety Relays ReLy
Real-life Examples
How these strengths come to the fore are demonstrated in two real-life examples with Flexi Compact. A machine builder in the plastics processing industry with in-house PLC development – for, amongst other things, injection molding, 3D printing and handling – was faced with the task, in developing the safety logic, of finding an easily integrated solution that allowed pre-configurable and codable cabling as well as seamless connection to the existing PLC architecture.
Flexi Compact met the requirements perfectly: The modular structure facilitates decentralized wiring, configuration can be implemented in a user-friendly manner via a Smartplug, and the front wiring simplifies the control cabinet layout and reduces error sources. The “Safety Configuration Deployment” tool further speeds up the programming process for machine series. The result was so impressive that Flexi Compact is now used series-wide in the customer’s machines and handling systems.
The requirements in automated cable processing were also high: A technology company was developing a new crimping machine for the automotive industry with the objective of significantly shortening the changeover times compared to the previous version and to establish a scalable safety architecture that functions consistently on both the main machine and the side modules.
Flexi Compact allows a flexible adaptation of the safety functions, multiple control stations on the main and secondary modules support a consistent machine architecture, and the efficient engineering in close technical collaboration made the integration noticeably easier. With this foundation, Flexi Compact is now used series-wide in the customer’s new and existing machine platforms.
Summary: Intuitive Safety Reduces Downtimes & Increases Productivity
These examples demonstrate: safety does not need to be complicated. As a standardized control platform, Flexi Compact can be smoothly integrated, quickly configured and intuitively operated. That increases the safety of people and machinery, boosts the system efficiency, lowers failure and maintenance costs and optimizes the overall productivity. Connecting Flexi Compact to higher-level machine controllers opens up additional integration options. The platform also supports companies in adequately addressing the cybersecurity requirements in current and future regulations – for example the EU Machinery Regulation.
The overall package is what makes the difference, however: By collaborating with SICK, machine builders and operators benefit from a comprehensive safety service – from a risk assessment according to EN ISO 12100 to holistic safety concepts to implementation of new systems, refurbishments or retrofits. This creates a powerful combination of technology, methodology and service for safe, efficient machine building. With safety.
For more information on SICK solutions HERE
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