PLC-Based Safety Automation

Hard-Stop Integration

Automatically stop machinery the instant Visionify detects a safety violation. AI-powered detection meets PLC-based physical response — preventing injuries before they happen.

<500ms

End-to-End Response

24/7

Continuous Monitoring

PLC Brands Supported

100%

Event Logging

Why Hard-Stop?

Traditional safety devices protect fixed zones. But what about the scenarios they can't see?

340,000+

hand and finger injuries per year in US manufacturing

Source: BLS

$46,000

average cost per machine-related injury incident

Source: NSC

42%

of machine injuries occur during non-routine tasks where guards are bypassed

Source: OSHA

What Triggers a Hard-Stop?

Visionify detects these safety events in real-time and signals your PLC to halt machinery immediately

AI detection overlay showing hands entering press brake danger zone with red bounding box alert

Hands in Restricted Area

Detects when a worker's hands enter a machine's danger zone — such as near a press brake, punch press, or conveyor pinch point — and immediately signals the PLC to halt the machine.

Example:

A press brake operator reaches past the light curtain to adjust material. Visionify detects the hand intrusion and triggers an immediate machine stop before the ram descends.

Worker entering robotic cell restricted zone with AI detection boundary overlay

Person in Restricted Zone

Triggers a hard-stop when anyone enters a defined danger zone around robotic cells, automated machinery, or hazardous process areas.

Example:

A maintenance worker steps into a robotic welding cell without lockout. The system detects the intrusion and stops all robotic movement instantly.

Operator at machine without gloves — AI highlights missing PPE with warning overlay

Missing Mandatory PPE

Stops machinery when a worker is detected operating equipment without required PPE — no gloves near chemical dispensers, no face shield at grinding stations, no safety glasses at cutting machines.

Example:

An operator approaches a chemical mixing station without gloves. The system prevents the dispenser from activating until proper PPE is detected.

Worker reaching into CNC machine with AI skeleton overlay detecting unsafe body position

Unsafe Posture or Behavior

Detects dangerous body positions or behaviors — reaching into running machinery, climbing on equipment, bypassing safety guards — and stops the machine before injury occurs.

Example:

A worker leans into a CNC machine enclosure while the spindle is running. Visionify detects the unsafe posture and triggers an immediate stop.

How It Works

From AI detection to machine shutdown in under 500 milliseconds

AI Detects Safety Event

Visionify's Edge AI continuously analyzes camera feeds and detects safety violations in real-time — hands in danger zones, missing PPE, unauthorized personnel, or unsafe behaviors.

Visionify Edge AI server analyzing multiple camera feeds with real-time safety detection overlays

Signal Sent to PLC

When a safety event is confirmed, Visionify sends a digital output signal to your PLC via standard industrial protocols — EtherNet/IP, PROFINET, Modbus TCP, or OPC UA.

Industrial Ethernet cable connecting Edge AI server to a PLC rack with status LEDs active

Machine Stops Immediately

The PLC executes the programmed safety routine — stopping the machine, retracting actuators, disabling outputs — based on your configured safety logic.

Industrial machine halted with safety indicator light showing red — hard-stop activated

Event Logged & Alert Sent

Every hard-stop event is logged with video evidence, timestamp, and trigger reason. Supervisors receive instant notifications via the dashboard, email, or SMS.

Visionify dashboard showing hard-stop event log with video snapshot, timestamp, and alert notification

Hard-Stop architecture diagram — Camera to Edge AI to PLC to Machine

Supported PLCs & Protocols

Works with all major industrial control platforms through standard protocols

Allen-Bradley (Rockwell)

ControlLogix, CompactLogix, Micro800

EtherNet/IP

Siemens

S7-1200, S7-1500, S7-300/400

PROFINET / OPC UA

Mitsubishi

MELSEC iQ-R, iQ-F, Q Series

CC-Link IE / SLMP

Omron

NJ/NX Series, CJ2, CP2

EtherNet/IP / FINS

Schneider Electric

Modicon M340, M580, M251

Modbus TCP / EtherNet/IP

Beckhoff

CX Series, C60xx

EtherCAT / OPC UA

Resources

Everything you need to integrate Visionify hard-stop with your PLC

PLC Configuration Guide

PDF · 24 pages

Step-by-step guide to configuring Visionify hard-stop triggers, PLC communication setup, safety zone definitions, and event-to-action mapping.

Download PDF

PLC Template Application

Open Source · MIT License

Open-source Python application that receives Visionify webhook events and translates them into PLC commands. Supports multiple protocols out of the box:

Modbus TCPSchneider, ABB, Wago, Delta, any Modbus-compatible PLC

EtherNet/IPAllen-Bradley ControlLogix, CompactLogix, Micro800

OPC-UASiemens S7-1500, Beckhoff TwinCAT, any OPC-UA server

Digital OutputRaspberry Pi GPIO, USB relay boards, industrial I/O

View on GitHub

Don't see your protocol? The handler architecture is modular — add a custom handler or contact our integration team.