This section provides an overview for safety controllers as well as their applications and principles. Also, please take a look at the list of 40 safety controller manufacturers and their company rankings. Here are the top-ranked safety controller companies as of November, 2024: 1.Schmersal GmbH & Co. KG, 2.elobau U.S., Inc., 3.J-KEM SCIENTIFIC, INC..
Table of Contents
A safety controller is a device that determines whether a machine is safe to operate and controlled based on signals received from safety input devices.
It can prevent a machine from starting, or force a machine to stop if it is unsafe to do so. Safety details are obtained by the use of electronic components and software based on functional safety standards
Safety controllers are used to monitor input devices, output devices, and the safety controllers.
They receive signals from input devices while the machine is running. Examples of input devices are emergency stop pushbutton switches or light curtains. The input device outputs an ON/OFF binary signal, and depending on the state of this signal, the safety controllers send a forced stop control signal to the output device or monitor the state of the input/output device.
If a machine failure occurs, self-diagnosis detects the failure and shuts off the machine's power by stopping the output. In the event of an abnormality, output devices can be safely stopped even if the operator is in a dangerous condition.
Hard-wired devices have been mainstream for safety reasons, but now that it is possible to configure safety circuits, electronic devices can be assured of the same quality as hard-wired devices.
The internal structure of safety controllers is designed and manufactured based on the concept of functional safety. The CPU performs mutual checks and back-checks on the input and output circuits, while the CPUs diagnose and monitor each other inside the device. Through these checks, the machine operates only when normal.
Safety controllers can be classified according to whether they are programmable or not, as follows:
Also called programmable safety controllers, these controllers allow the creation of safety control programs that are specific to the machine. Therefore, they can flexibly respond to cases in which complex logic needs to be constructed.
Generally called safety relay units, these products range from those that support one pair of inputs and outputs each to those that have multiple inputs and outputs and can be used to build simple safety control circuits.
Depending on the product, safety control circuits can be easily built without programming, allowing for total and partial shutdown.
To prove that a safety controller is safe, it must be based on a functional safety standard.
Functional safety standards are based on the idea that things will break, and people will fail. The measures that reduce the allowable risk are determined in relation to the scale of damage caused by failures and errors.
The level of countermeasures according to the scale of damage is called the safety integrity level. Safety Integrity Levels (SIL) are divided into four levels, with Safety Integrity Level 4 requiring the highest level of countermeasures and Safety Integrity Level 1 requiring the lowest level of countermeasures.
Based on functional safety standards, it is defined "as determining the level of countermeasures according to the magnitude of damage, and using records such as design basis and manufacturing process to explain to a third party that the countermeasures correctly reflect the level of damage."
There are four types of safety controller programs, namely: ladder, flowchart, stepladder, and SFC (Sequential Function Chart). The ladder method is the most commonly used of the four, And it is called a ladder diagram or ladder program because its description format resembles a ladder.
A relay is an electronic component that switches ON or OFF by an external electrical signal. In a relay sequence, an input relay controlled by an external input, such as a sensor, and an output relay controlled by an external output, such as a motor, turns on or off the output relay when the conditions of a timer or counter are met.
The disadvantage of ladder programming is that it is difficult to modify the system because the programming software differs from one safety controller's manufacturer to another.
At a minimum, the safety controller must meet functional safety standards, such as those listed below:
Investigate the Cause of a Forced Machine Shutdown
In some cases, an input device or safety controllers may determine that a machine is in danger and force it to stop, even though it is not in fact in danger. The system must be able to investigate the cause in a short period to determine if the machine was really in danger or if it was based on a malfunction.
Ease of Operation.
When a safety controller is purchased, wiring and program implementation are required. If these tasks require a lot of man-hours when starting up or reassembling a production line, production efficiency will be reduced.
*Including some distributors, etc.
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Electro-Sensors, Inc. operates as a manufacturer of precision sensors and monitoring systems, established in 1968 and headquartered in Minnesota. The company specializes in providing products and services for industries such as industrial manufacturing, agriculture, and material handling.Its offerings include speed sensors, temperature sensors, and hazard monitoring systems. These products are used for precision monitoring and safety assurance, enhancing operational efficiency and safety measures in the industries it serves through its precision sensor and monitoring solutions.
Columbus McKinnon Corporation, founded in 1875 and headquartered in Charlotte, North Carolina, is a manufacturer of intelligent motion products used for automation, conveyance, lifting, and linear motion. Its product range includes handheld transmitters, flexible chain conveyors, lever hoists, industrial linear actuators, and pallet systems used in several industries, including aerospace, entertainment, automotive, metals production, and pharmaceutical. The company is ISO 9001 certified and has manufacturing facilities across Africa, Asia, Europe, Latin America, and North America. It has several brands, including STAHL Crane Systems, Dorner Conveyors, Duff-Norton, Magnetek, and Unified Industries.
ERDCO Engineering Corp. is a manufacturer of flow measurement instruments established in 1946 and based in Evanston, Illinois, USA. The company specializes in instruments for measuring liquids and steam in industrial processes. These products include flow switches for flow or no-flow indication, flow rate meters for direct reading of flow rate, and flow totalizers for providing total flow or batch control. The company’s products are mainly used in the industrial processing sector, with additional applications in food and beverage processing and wastewater management.
J-KEM SCIENTIFIC, INC., established in 1987, and headquartered in St. Louis, Missouri, USA, is a manufacturer of precision thermal control systems for laboratories. The product range includes temperature control instruments, reaction systems, and laboratory automation equipment. These products offer precise temperature control, reproducibility, and improved experimental accuracy for scientific research. The benefits of the products include enhanced research outcomes, reduced experimental variability, and increased efficiency. The company serves industries such as pharmaceuticals, chemical research, material science, and biotechnology, providing essential thermal control solutions that support precise experimentation, increase productivity, and result in advancements in various scientific fields.
Pepperl+Fuchs, Inc. was founded in Mannheim, Germany in 1945 developing the forerunner of the proximity switch. Pepperl+Fuchs continues to develop proximity sensors as well as other industrial sensors including ultrasonic sensors, rotary encoders, positioning systems, display and signal processing, vibration monitoring, industrial communication, and signal processing as well as related accessories and software. Explosive protection products include safety barriers, surge protection, wireless solutions, HMI systems, power supplies, electrical explosion protection equipment, level measurement, and related software.
Banner Engineering Corporation, established in 1966 and headquartered in Minneapolis, Minnesota, is a manufacturer and supplier of industrial automation products. They offer an extensive range of sensors, including proximity sensors, photoelectric sensors, and limit switches, for detecting object presence, position, and speed. Additionally, Banner provides a different types of switches, such as pushbuttons, toggle switches, and rotary switches, to control electricity flow and offer system feedback. Their wide array of controls includes PLCs, HMIs, and motion controllers, enabling automation of industrial processes.
ifm efector (ifm) is a subsidiary of ifm electronic, founded in Germany in 1969. ifm has developed, manufactured and marketed sensors and controls technology to industries that include assembly and robotics, automotive, material handling, metal forming, mobile equipment, plastics, and food and beverage. Ifm produces sensors, condition monitoring equipment, image processing, safety technology, industrial communication, IO-link, systems for mobile machines, displays, software, connection technology, voltage supplies, as well as other accessories.
Sick AG, founded in 1946 and headquartered in Waldkirch, Germany, is a manufacturer of sensor and sensor solutions that aid in in production, logistics, and processes automation. The company’s expansive product portfolio includes industrial sensors, encoders, and analyzers. It has over 50 subsidiaries and equity investments as well as several agencies worldwide, and in the 2022 fiscal year, it generated around €2.2 billion. The company established the first subsidiary in France in 1972 and opened another subsidiary in USA in 1975. It changed to a joint stock company in 1996 and the first employee shares were issued in 1999.
elobau U.S., Inc., founded in 1972 and headquartered in Waukegan, Illinois, is a designer, manufacturer, and supplier of sensor technology solutions for automotive and industrial applications. The company has interests in four business verticals: automotive engineering, sensor technology, filling level measurement, and machine safety. Its products include safety controllers, safety sensors, angle sensors, emergency stops, and other related products designed to help clients in challenging environments such as ATEX and food packaging applications. The company delivers its products worldwide, backed by a network of subsidiaries and distributor partners.
The Carlo Gavazzi Group is a multinational company that was established in 1931 in Milan, Italy, known for designing, manufacturing, and distributing electronic equipment and automation solutions. The company offers a wide range of products that includes automation components such as monitoring relays, sensors, timers including electronic controls. There are also energy management solutions, and these products are supplied to industrial manufacturers of semiconductors, plastic machinery, agriculture, HVAC, and mobile equipment to name a few. Building automation companies and renewable energy services also benefit as they streamline their operations, reduce energy costs, and increase productivity.
LIKA Electronic, established in 1982, is based in Buccinasco, Italy, and is a manufacturer and supplier of encoders, position measuring systems, and linear motion components. Their product portfolio includes rotary encoders, incremental and absolute encoders, linear encoders, and magnetic measuring systems. These precision devices find applications in various industries, such as automation, robotics, CNC machines, and packaging equipment. LIKA Electronic's products are known for their accuracy, and durability, providing essential feedback for motion control and positioning. Putting a priority on client happiness and creativity, LIKA Electronic continues to deliver cutting-edge solutions that meet the evolving needs of the industrial automation market.
Pilz is headquartered in Ostfildern, Germany. Pilz designs components, systems, and services to assist industrial plant and machinery customers globally. Customers include many industries such as metals, pharmaceutical, food, presses, and robotics. Pilz serves customers through 4 venues: products and industries, services, support, and training. Products and services include everything from sensor technology and small controllers to robotics to software and operation monitoring. Services include machinery and workplace safety and international compliance. Support is offered 24/7. Training is available through courses and qualification programs.
Turck was founded in 1965 and is headquartered in Mülheim an der Ruhr, Germany. The company is a global manufacturer of automation machinery used in the automotive, energy, chemical, food, and packaging industries among others. The company’s products integrate the concept of Industry 4.0 technologies such as RFID, IO-link, and ethernet to assist factory and material handling equipment in communicating with other equipment and providing data for operators to improve efficiency and safety while decreasing waste. These products include sensors, industrial controls, industrial wireless and vision devices, and interface devices.
Jining KeLi Photoelectronic Industrial Co, Ltd, established in 1997 in Jining, Shandong, China, is a manufacturer of photoelectronic protection products and equipment. The company specializes in manufacturing safety light curtains that protect against various photoelectronic machines such as lasers, and infrared devices. The comprehensive product line includes safety light curtains, automation light curtains, laser markers, and safety controllers, to name a few, for application in multiple industries. The products are used in hazardous machine industries such as electronics, rubber, plastics, automotive, and packaging industries for their efficient protection, enhanced productivity, and longer durability.
Leuze was founded in Owen/Teck in Southern Germany in 1963 as a manufacturer of sensors. The company's product range encompasses switching and measuring sensors, identification systems, data transmission, and image processing solutions which are further classified as optical sensors, inductive switches, area scanners, IP cameras, and various cables and connectors. They serve a broad spectrum of industries including machine tools, packaging, automotive, intralogistics, and laboratory automation where they provide sensor solutions for various processes
Wieland, established in 1910 and based in Bamberg, Germany, is a manufacturer and supplier of electrical connection technology. Their product range includes pluggable connections for seamless plug-and-play electrical device connections, insulated connectors that provide electrical insulation in device connections, cable glands for safeguarding cables and ensuring a watertight seal, terminal blocks used for connecting electrical wires, and contact systems facilitating connections between electrical components. Wieland's products find applications in diverse industries, such as building construction, electrical engineering, and automation.
IDEC Corporation was founded in 1945 and is headquartered in Japan as the manufacturer of automation and control products. The company provides solutions that meet the evolving needs of customers. With a focus on areas such as IoT implementation, automation advancements, and manufacturing site safety, IDEC offers a diverse range of products such as electromechanical control products such as relays, timers, and switches. The company also manufactures automation products, such as Micro Programmable logic controllers, power supplies, and touch-screen displays. Their goal is to help businesses adapt to changing technologies, improve operational efficiency, and prioritize safety in industrial environments.
Schneider Electric S.E. is headquartered in Rueil-Malmaison, France, and has been operating since 1836. Schneider Electric provides a number of products and services including electrical car charging, energy management software, surge protection devices, load banks, servers and HMIs, valve and valve actuators, feeder automation, grid automation, and SCADA software products, data center cooling and software, home automation and security, light switches, motion control and robotics, signaling units, solar and energy storage, RFID systems, as well as other hardware, services, and software.
ReeR S.p.A., founded in 1959 in Turin, Italy, is a manufacturer of optoelectronic sensors and controllers for industrial safety. Its products, including laser scanners, contactless interlocks, and photocells, are essential in manufacturing, robotics, automotive, and packaging industries. The company's innovation culture and adherence to ISO9001 specifications lead to the highest level of protection for workers and equipment and make products appealing to global clients. ReeR S.p.A provides technical support and know-how for clients to select, install, and maintain safety solutions.
ST Micro Electronics is a global semiconductor company serving customers with innovations to have a positive impact on people's lives. Their product line is micro electronic systems, such as switches, controllers, sensors and drivers. The main selling point of ST Micro Electronics is its provision of sustainable products, and introducing their electronics to create a more sustainable world. The company, as well as providing the electronic devices, also provides software and support, ensuring that all fields are covered to provide a fully provide a supported and strong relationship with their customer base. ST Micro Electronics believe that technology plays a key role in helping to solve environmental and social challenges, which is why their semiconductor technologies start with their employees, their customers and partners.
WEG S.A. is an ISO 9001-certified manufacturer of industrial engineering products founded in 1961 and based in Jaraguá do Sul, Brazil. The company produces equipment and products for power generation, control, and coating metal or wood. These include powder coatings for decorative or protective purposes, gas turbines, and dry-type transformers. The company primarily serves clients in the oil and gas, wastewater processing, and mining industries. It also offers maintenance, engineering, and automation services to its customers.
B&R Industrial Automation GmbH, founded in 1979 with headquarters in Austria, is a manufacturer of automation technology, including a complete portfolio of robotics, automation, and software. The company's standard and tailored products are used in the automotive, maritime, medical device assembly, packaging, and plastics markets, among many others. The product line includes industrial PCs, I/O systems, robotics, and software for industrial components. B&R joined the ABB Group in 2017 to specialize in the integration of technology and sophisticated engineering to provide industries with solutions for machine and factory automation, motion control, and integrated safety technology.
Honeywell, founded in 1906, in Wabash, Indiana is manufacturer of automotive parts, building technologies, and performance and safety materials for aerospace, The company's product portfolio includes electronic guidance systems, cockpit instrumentation, lighting, automotive parts, and primary propulsion and secondary power turbine engines. The company serves industries such as Oil and Gas, Aerospace and Defense, Automotive and Transportation, Construction, and Power Generation. Their headquartere is located in Carolina and they have global sales offices and distributions channels.
Founded in 1890 in Missouri, Emerson Electric Co., is a technology and engineering company that provides various solutions for customers in industrial, commercial, and consumer markets globally. Business segments include automation solutions, AspenTech, and commercial & residential solutions segments. The Automation Solutions segment offers measurement and analytical instrumentation, industrial valves and equipment, and process control software and systems. The AspenTech segment provides asset optimization software for enhancing performance through a combination of modeling, simulation, and optimization capabilities. The Commercial & Residential Solutions segment offers residential and commercial HVAC products, system protector and flow control devices, and IoT thermostats.
Omron Corporation, started in 1933 and headquartered in Kyoto, Japan, is a manufacturer of automation components, equipment, and systems, and it developed the first contactless proximity switch in 1960. It has four domains, including industrial automation, electronic components, healthcare, and social systems, and it provides products and services in around 120 countries and regions. Some of its products include microsensing devices, access control systems, industrial robots, surveillance cameras, and blood pressure monitors. In 1971, it developed the first online cash machine, and in 1972, it established Japan’s first welfare factory.
Schmersal GmbH & Co. KG, founded in 1945, by Heinz and Philip Schmersal, is a name in safety technology, is a manufacturer of safety technology solutions, specializing in switchgear and control devices for various industries. With a diverse range of mechanical and electro-sensitive switching devices, they offer an extensive collection of safety switching systems and devices for safeguarding both humans and machinery. The company looks after three key domains: lift technology, automation technology, and safety technology. Their substantial approach position them as a global supplier of safety switching devices, catering to the safety and automation needs of various industries.
ABB E-mobility provides electric vehicle charging solutions for customers around the globe. ABB E-mobility offers DC fast chargers as well as AC chargers with focus on reliability and uptime. Since 2010, ABB E-mobility has sold over 50,000 DC fast chargers and over 1 million total AC chargers. ABB E-mobility offers home single and multi-charge units, retail, workplace, and hospitality charge units, electric vehicle fleet sales, as well as public transportation. Additionally, numerous digital solutions and software services are available.
Phoenix Contact is headquartered in Blomberg, Germany, originally founded in 1923. Phoenix Contact’s Israeli subsidiary was founded in 2006 and located in Quadima Tzoran. Phoenix Contact provides tools and components for e-mobility, power, infrastructure, process industry, production manufacturing, system manufacturing, and others. Phoenix Contact’s product lines include automate including cloud computing, connect including PCB terminal blocks, “mark, assemble, and install” including hand tools, “supply, charge, and protect” including power distributors, and “switch, measure, and monitor” including relays and optocouplers.
BERNSTEIN AG is a manufacturer and distributor of electromechanical components that was established in 1947 in Germany. The company manufactures switches and sensors that range from insulated and metal enclosed to foot switches and safety switchgear. They also provide enclosure technology that deals with the implementation of support systems for various applications such as using housing to accommodate electrical, electronic, or pneumatic components and load-bearing systems made of aluminum and stainless steel. They also offer safety solutions related to the operation of lifts and escalators that are placed in malls and airports
SMC Electric, a company founded in 1950, based in Missouri, USA, is a distributor and supplier of electrical, automation, industrial, data comm, and fluid power products and services. The company offers a range of products from important manufacturers such as SMC USA, Rockwell Automation, Eaton, and Siemens. These products are used in various industries such as manufacturing, government, energy, and food and beverage. It also provides customer services that include technical support, training, catalog request, and customized solutions.
Rockwell Automation, Inc. was founded in 1903 and is headquartered in Milwakee, WI. Rockwell Automation provides industrial automation and digital transformation solutions around the world. Rockwell Automation operates through their intelligent devices, software & control, and lifecycle services segments with both hardware and software products and services. The Intelligent Devices segment offers drives, motion, safety, sensing, industrial components, and configured-to-order products. The Software & Control segment provides control and visualization software and hardware, information software, and network and security infrastructure solutions. The Lifecycle Services segment provides consulting, professional services and solutions, and connected and maintenance services through independent distributors.
PMC-STS Inc., founded in 1963 and based in Danbury, Connecticut, is a manufacturer of pressure, vacuum, and level sensor instruments for aerospace, motorsports, and water applications, among others. The company also provides customized solutions and products to meet challenging customer requirements. It is the first manufacturer offering flush-mounted transmitters for measuring in-process pulp in wastewater, paper, and other difficult fluid level and pressure measurements. In 2022, the company was acquired by Sensor Technik Sirnach AG to help penetrate the North American market further and benefit from both application and product expertise.
MFP Automation Engineering, founded in 1991 and based in Hudsonville, Michigan, is a manufacturer and distributor of fluid power, motion control, and automation products. It stocks products such as fire suppression systems, hydraulics, and connectors and has over 80,000 SKUs in inventory from brands like ACE, SKF, and Parker. It even has an on-site Parker store that stocks thousands of ready-to-go parts like servo motors and hose assemblies. The company is ISO 9001 certified and provides on-site installations, filtration analysis, and systems engineering services. Its CNC vertical machining centers range from five to twenty-five spindle horsepower.
Technology BSA S.P.A established in 1997, is a supplier of automation, electrical and electronic products based in Turin, Italy. The company's supply portfolio includes cables, sensors, pneumatics, trays and mechatronics. It has been a part of the Edge Global Supply Group since 2017. Its main partners include Rockwell Automation, Phoenix Contact, Festo, Prosoft Technology and Cognex Corporation. The company also offers training courses on how industrial sensor technology can be used in plants to improve efficiency.
Proax Technologies Ltd., established in 1962 and based in Mississauga, Canada, is a distributor and supplier of automation product solutions. The company's product range includes power products, connectors, contactors, pneumatics, and terminal blocks. These products are used for automation machinery manufacturing. They primarily serve industries such as automation & robotics, motion control, machine safety, and technical support. The company offers services like technical support, design, build, and assembly for mechanical, electrical, and process applications.
Ranking as of November 2024
Derivation MethodRank | Company | Click Share |
---|---|---|
1 | SICK AG |
5.2%
|
2 | WEG S.A. |
4.8%
|
3 | Schmersal GmbH & Co. KG |
4.4%
|
4 | elobau U.S., Inc. |
4.4%
|
5 | J-KEM SCIENTIFIC, INC. |
4.4%
|
6 | Leuze electronic GmbH + Co. KG |
4.4%
|
7 | ifm efector, inc. |
4.4%
|
8 | ReeR S.p.A. |
4.0%
|
9 | B&R |
4.0%
|
10 | Electro-Sensors, Inc. |
3.6%
|
Derivation Method
The ranking is calculated based on the click share within the safety controller page as of November 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
Country | Number of Companies | Share (%) |
---|---|---|
United States of America | 9 | 37.5% |
Germany | 5 | 20.8% |
Italy | 4 | 16.7% |
Japan | 2 | 8.3% |
United Kingdom | 2 | 8.3% |
China | 1 | 4.2% |
France | 1 | 4.2% |
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