Multi-sensor AI safety that sees, senses and stops — before a worker becomes a statistic. A light curtain guards one plane of air and then forgets you. Monolith watches the whole working volume, continuously, and will not let the machine start while anyone is still inside.
Four configurations, each adding a layer of sensory certainty. From entry factory surveillance to full autonomous hazard intervention — every tier is a complete system, not a starter kit.
Light curtains, floor-mounted laser scanners and IR beams detect a single crossing of a single plane — once. They cannot tell whether a person is still inside. Monolith watches the entire volume, continuously, in 3D.
A light curtain registers a person crossing the beam — then forgets them. If the worker is still inside the cell when a colleague presses RESET and START, the palletizer runs. People die this way. Monolith continuously tracks every person inside the zone and inhibits the start while anyone remains — presence-aware, not just crossing-aware.
A cell has only a handful of gates. Monolith counts every person in and out, so it always knows the live occupancy of the zone — and inhibits restart until occupancy is provably zero. This solves the "whole-body access" gap (ISO 13855) that light curtains physically cannot: a worker who steps through and stands inside is still counted as present, even if no interior sensor can see them.
Blind sensors halt the line for anything that breaks the beam — a box, a forklift, a swinging pallet. Monolith classifies what it sees, so it stops for a human and ignores product. Fewer nuisance stops means operators stop bypassing the guarding — the single most common root cause of guarding-related fatalities.
Pilz radar, SICK IR scanners and light curtains sit at knee-to-waist height on the floor line — directly in the path of forklifts, pallets and impacts. Our sensors mount overhead: nothing to clip, kick, mis-align or smash. Fewer nuisance faults, far longer service life, no realignment call-outs.
A PLC stores numbers; it cannot reason about them. Monolith reads your PLC and camera streams in real time and turns them into insight, foresight and evidence.
A pallet falls off the robot arm at 2am. Instead of scrubbing eight hours of footage, the plant head gets an instant alert and a ready-made clip — the anomaly timestamp ±1 minute of video. The event finds you.
Our tracker predicts each person's trajectory ~1 second into the future. The system can stop the hazard before the worker reaches it — pre-emptive intervention, not just reaction. A reflex, not an alarm.
We read PLC tags and logs in real time and surface analytics, correlations, root-cause and predictions the controller can't produce on its own — stop causes, alarm patterns, downtime drivers, all explained in plain language.
The plant head sees live detections, analytics, heatmaps and event logs from any browser — on-site or off. Full visibility of every protected cell, without standing on the floor.
Rotary fillers running hydrochloric toilet cleaner, hypochlorite bleach and other corrosive product are a harder guarding problem than a robot cell, for reasons that have nothing to do with the robot. Specifics, not generalities:
Changeover, nozzle swaps and CIP put a person bodily inside the cell. An interlocked guard door proves the door is shut — never that the cell is empty. Monolith inhibits the start until the human-accessible envelope is provably clear, and holds it there.
Nozzles, star wheel, infeed screw, bowl, piping and bottles in process mean almost every point inside the cell is legitimately occupied. A sensor asking “is anything present?” can never issue a restart. Monolith asks a narrower and answerable question: is the envelope a person can actually occupy clear?
Under the nozzle bank, inside the bowl and behind the star wheel are occluded from any mounting position — that is geometry, not a product limitation. The system reports its own coverage and names the regions it cannot certify. A stated blind region is safer than a false green, and it is what an auditor can actually act on.
Caustic CIP destroys ordinary depth cameras — most are USB-C and do not survive one cycle. Sensors are IP67-rated with M12 X-coded power and data, and sited at standoff outside the wash zone rather than enclosed inside it.
HCl and hypochlorite aerosol pit 304 stainless and degrade housings, cable glands and lens coatings — a rating chosen for a dairy or a brewery is the wrong rating here. Mounts, enclosures and cable entries are specified against the actual product chemistry, and sensors are kept out of the aerosol plume at the nozzle bank.
Post-CIP water film and spilled product are the single largest source of nuisance trips in a filler, and a polished deck is close to the worst case for depth sensing. A spill is handled as a degraded-visibility condition to be reported, not as an object to stop the line for.
Vibration walks sensor alignment out of calibration over a shift. Monolith continuously checks its own extrinsics and signals the controller when a sensor has moved, been blinded or been obscured — rather than quietly reporting a clear cell it can no longer see.
In an acid cell the route to the safety shower is part of the safety case. Obstruction of a marked egress path is a zone condition Monolith can flag and log, alongside the guarding function.
A spanner left on the deck is a foreign-object and contamination problem, not a guarding one — that is TesseRack. Whether the operator is wearing the face shield, gauntlets and apron the acid demands is Forge. Keeping them apart is what keeps the safety claim clean.
Filler-cell guarding is in design, not deployed. Sensor siting, achievable coverage and the restart-clearance envelope are established per cell at survey and proven on the actual deck before anything is quoted — a polished stainless filler behaves differently enough from a palletizer that carrying numbers across from one to the other would be dishonest. As everywhere else on this site: engineered to the principles of ISO 13849 / IEC 62061, with formal third-party certification on our roadmap.
Blind sensors halt the line for anything that breaks the plane — and every one of those needless stops is lost production. Because Monolith knows a person from a product, the machine stops only when a life is genuinely at risk. We measured the difference on a live palletizing line.
Figures from continuous PLC + vision logging on a real line; they scale with your line speed, shift pattern and product value. A live dashboard reports avoidable minutes and rupees recovered, updated every shift — so the safety system also reads as a productivity investment to your finance team, not just a cost.
An autonomous, audit-trailed stop function is the floor, not the ceiling. The same sensors that protect your people quietly de-risk your balance sheet, your insurance and your uptime.
Monolith answers one question: is a person inside the working volume, and may the machine run at all? Forge answers a different one at much closer range — what is at the tool right now — and it stops the machine too. The two are separate products because a sensor placed to see a whole cell is rarely placed to see a hand at a blade. TesseRack inspects the load and never stops anything.
Tell us about your facility. We'll identify the right sensor configuration, generate a full BOM, and walk you through compliance requirements — at no cost, no obligation.