Why integrated safety technology is indispensable in industrial automation
- Digitalization
- 8.4.2026
- Reading Time: {{readingTime}} min
Contents
IT and OT systems in industrial plants are networked. This creates larger attack surfaces and interfaces.
What are the benefits of integrated security solutions in automation technology?
In a modern machine architecture, safety can only deliver its full benefits if it is seamlessly embedded in the automation platform and ergonomically incorporated into the machine and operator interface design. A uniform system basis reduces interface effort, simplifies diagnostic processes, and ensures that safety-related information is processed without media discontinuity. This reduces variant diversity and cabling complexity right from the basic design stage.
Closely integrated safety and automation technology also increases plant availability: Integrated systems continuously monitor movements and states, detect potential malfunctions at an early stage, and can compensate for them intelligently without interrupting entire processes. This leads to shorter downtimes and faster fault diagnosis, as all relevant data is available centrally.
What are the challenges involved in implementing integrated security technology?
Implementing integrated security technology is complex because modern industrial plants must meet numerous normative, technical, and organizational requirements. IT and OT systems in industrial plants are increasingly networked. This creates larger attack surfaces and interfaces that must be properly secured. Without expert support, security gaps can arise - especially when companies use individual tools or isolated security measures that are not fully integrated. Standards such as IEC 62443, ISO 27001, EN 50742, NIS 2, and the Cyber Resilience Act place high demands on documentation, risk assessment, and implementation. Safety experts can help to meet these requirements correctly and efficiently and avoid typical implementation errors.
How can security solutions be used in different industries?
Integrated safety technology is ideal for a wide range of industrial applications that require the highest safety standards and flexible configuration options. Modular safety solutions in particular can be more easily adapted to different machine options and variants thanks to their scalability. This provides reliable protection for robot systems, machines with hazardous movements, and packaging, assembly, and production systems, for example. Adaptable safety configurations are also a great advantage in special-purpose machine construction and series machines, which often require highly customized safety concepts. Rapid adaptability and standards-compliant safety - for a wide range of machines, from robots to complete systems - are therefore particularly valuable in an industry where variety, time-to-market, and safety are becoming increasingly important.
How do KEBA security solutions work?
Functional safety plays a crucial role in industrial automation. KEBA's KeSafe safety technology includes solutions that enable machines, robots, and humans to interact reliably with one another. The system is scalable and flexible - ideal for modern industrial plants. KeSafe combines a powerful safety solution with certified function blocks, enabling the fast, flexible, and standard-compliant implementation of modern safety requirements in industry and robotics. The system has a modular design and offers companies maximum scalability and easy integration into a wide variety of applications. The KeSafe safety solution comprises three clearly defined function levels that are optimally tailored to different safety requirements.
The KeSafe function levels:
- KeSafe PLC for safe logic functions.
- KeSafe Motion for safe axis applications.
- KeSafe Robotics for safe robot functions.
Our KeSafe safety technology follows precisely this safety by design principle: fully integrated, scalable, and designed for the most demanding requirements up to category 4 / PL e and SIL 3 – ideal for demanding applications such as robotics and complex machines.
The system has a modular design and offers companies maximum scalability and easy integration into a wide variety of applications.
Example of a mechanical engineering automation solution with integrated safety technology
What advantages do freely programmable applications offer?
In industrial automation, the demand for flexible, efficient, and standard-compliant safety solutions is constantly increasing. Freely programmable software for integrated safety technology plays a central role here, as it enables companies to customize safety functions to their machines, systems, and production processes. Freely programmable safety systems such as KeSafe from KEBA allow safety logic to be defined individually and adapted to a wide variety of machine options, system types, and variants. This allows both simple logic functions and complex motion and robot safety applications to be configured flexibly.
KEBA's KeSafe can be freely programmed using the intuitive KeStudio SafeEdit engineering tool. This software makes it easy to create safety applications, edit them graphically, and validate them in accordance with standards. SafeEdit supports engineers in efficiently implementing even complex safety logic – from planning and implementation to final acceptance. Thanks to reusable, certified function blocks, the system can be adapted to a wide variety of machine variants and robot types.
“The future of automation is software-defined – and integrated safety technology is a natural part of it.”
Conclusion: Seamless integration for maximum plant and machine safety
With KeSafe, KEBA has developed a powerful, flexible, and comprehensive safety technology solution that meets the requirements of modern industrial automation. KeSafe ensures maximum operational safety, increases plant flexibility, and enables new forms of human-machine interaction. KeSafe is the right choice for companies that want to combine efficiency, scalability, and the highest safety standards.
Professional support for application development and commissioning
KEBA supports companies right from the early stages of their projects. The company offers comprehensive support for the development of safety applications and the commissioning of machines and robots. This enables users to ensure that all safety functions are correctly implemented, tested, and executed in accordance with current standards.Efficient engineering thanks to KeStudio SafeEdit
With KeStudio SafeEdit, KEBA provides a powerful engineering tool that supports users in creating, programming, validating, and diagnosing safety applications. The software enables intuitive, graphical editing of safety logic and significantly simplifies troubleshooting.Certified function modules for rapid implementation
KEBA provides certified, reusable function modules that enable users to implement safety circuits quickly, custom-designed, and in compliance with standards. These modules can be combined flexibly, which reduces effort and increases application safety.Smooth operation thanks to optimal cooperation between safety and automation
The KeSafe safety solution is designed to work seamlessly with machine and robot control systems. This enables invisible but highly effective safety operation without disrupting the production flow. For users, this means less complexity, fewer downtimes, and significantly more stable system performance.
