In the demanding world of industrial automation, delivering performance and safety in equal measure is key — especially when it comes to high-output, high-precision applications in the automotive sector. An Italian company specialized in the development of automated production lines has recently completed a state-of-the-art project for a long-standing client: an international manufacturer of thermostat housings. The challenge was to combine productivity, reliability, and safety into a highly modular and scalable production line — and ReeR’s modular safety platform MOSAIC proved to be the perfect fit.
The Application: Advanced Automation with Selective Safety
The new line, implemented in 2022, extends over 14 meters and integrates 16 operational stations grouped into five main functional zones. While fully automated, the line still involves operator interaction at the initial loading and final packaging phases. With an average cycle time of 35 seconds per piece, the system is optimized for high throughput and high quality. Each zone of the line is independently operable, allowing localized stoppages without impacting the overall workflow — a key requirement from the client. This modularity enables streamlined intervention and maintenance, with minimal downtime.
To meet stringent safety and performance standards, every zone is equipped with:
Emergency stop devices with energy isolation
Fixed guards and interlocked movable guards
Safety light curtains for operator access protection
Independent air handling units(AHUs) with centralized distribution
Safety Requirements: Independence, Diagnostics, and Expandability
Given the line’s complexity and the customer’s focus on operational continuity, the safety design called for:
Independent safety management for each zone
Selective control of emergency stops, interlocks, and light curtains
Pneumatic and electrical isolation by zone, including axis control
Future-proof architecture with safety I/O available for expansion
Reduced wiring and simplified programming via centralized
control
Every zone required at least:
Four dedicated safety inputs
STO and interlock management outputs
Local signal collection and diagnostics modules
Outputs for robot integration in selected areas
ReeR’s Solution: The Modular Power of MOSAIC
To respond to these requirements, the integrator selected ReeR Safety’s MOSAIC — a modular safety controller that enables flexible, decentralized safety architectures with centralized logic and diagnostics.
At the core of the system is the M1S COM module, featuring:
8 digital safety inputs
4 OSSD outputs (2 pairs)
4 test outputs
Dual RJ45 ports for fieldbus communication (EtherCAT, PROFINET, Modbus TCP, Ethernet IP)
To support distributed safety control, the architecture was expanded with:
MI16 and MI8 input modules for collecting emergency stop, light curtain, and interlock signals
MO4 output modules fdor actuating valves, relays, or other safety devices
MCT1 and MCT2 communication modules to interface with remote I/O boxes via the MSC bus
Thanks to this modular approach, each functional zone operates as an autonomous safety cell — connected, yet independent. Operators can safely intervene in one area without halting the rest of the process, ensuring operational continuity & quick maintenance turnarounds.
Safety, Efficiency, and Scalability
The deployment of the MOSAIC platform delivered measurable improvements in both safety and productivity:
Scalability: Easy integration of new sensors or stations as the line evolves
Reduced installation times: Simplified wiring through decentralized modules
Zone-based safety management: Operational autonomy across functional areas
Advanced diagnostics: Real-time insights and simulation via the free MSD software
Minimized downtime: Targeted machine stops for maintenance or faults
Streamlined operations: Standardized components and simplified spare parts management
Built for the Future of Industrial Automation
This successful implementation demonstrates how a tailored approach to safety – powered by ReeR’s modular technology – can help manufacturers meet the ever-increasing demands of performance, traceability, and flexibility in modern production environments.
Whether in standalone test benches or complex, multi-zone production lines, MOSAIC stands out as the go-to solution for industrial safety that doesn’t compromise on performance. With its robust architecture and intuitive software tools, it empowers machine builders and end users alike to design, operate, and maintain automation systems with maximum confidence.
Ready to future-proof your production line with modular safety?
Discover how ReeR’s MOSAIC platform can enhance safety, streamline operations, and scale with your needs — without compromising on performance.
Contact ReeR Safety and elevate your automation today!
For more information,
www.reersafety.com