Automation and autonomy are redefining how mobile machines operate—and how they must be kept safe. In industries where telehandlers, aerial lifts, or utility vehicles operate near risk-intensive environments, safety is no longer a compliance checkbox—it’s a performance differentiator.

Baumer, a leader in industrial sensing, is powering this evolution with Functional Safety sensor solutions that help OEMs design smarter, safer, and more future-ready machines.

Why Functional Safety Matters

Functional Safety is about ensuring a machine continues to operate safely even when faults occur. It bridges electronic, mechanical, and control systems to prevent injuries or damage—automatically.

Rising regulations under ISO 13849 and IEC 61508, together with skill shortages and the push for uptime, demand new levels of precision and intelligence in safety systems. Baumer sensors enable OEMs to meet these growing expectations—combining diagnostics, fail-safe design, and rugged industrial performance.

Understanding SIL and PL: Two Standards, One Mission

In Functional Safety, engineers frequently reference two rating systems:

• SIL (Safety Integrity Level) from IEC 61508/IEC 62061—used for programmable controls and systems

• PL (Performance Level) from ISO 13849-1—used for discrete, electromechanical systems

Baumer’s PLd and SIL2-rated sensors ensure safe operation by maintaining ultra-low Probability of Dangerous Failure per Hour (PFH)—translating to up to a century of safe performance under defined conditions.

Field Hazards That Demand Smart Sensing

According to the IPAF Global Safety Report 2024, the most common fatal events in mobile elevating work platforms (MEWPs) are:

1. Falls from platforms

2. Electrocution

3. Entrapment or crush injuries

4. Machine overturns and instability

5. Mechanical or software failure

Each scenario underscores the critical role of live system feedback. Baumer’s sensors deliver real-time monitoring for inclination, load, and position—eliminating guesswork and enabling precise, proactive safety control.

Baumer’s Functional Safety Portfolio In Action

Static Stability and Load Control

Meeting EN 280 standards requires accurate monitoring of outrigger position, boom angle, extension, and load. Baumer’s certified sensors offer a comprehensive solution set:

• GIM600R Inclination Sensor
  PLd-rated high-precision tilt sensor, engineered for harsh outdoor conditions and redundant interface options (CANopen, J1939).

• GCA5 Cable Transducer
  Non-contact magnetic draw-wire transducer for linear position feedback up to 7.8 m, IP67-rated.

• EAM580R Absolute Encoder
  ISO 13849-compliant, robust encoder for motion feedback, offering long lifespan and resistance to vibration and corrosion.

• PP20S Pressure Sensor
  Compact PLd-compliant sensor for hydraulic pressure and load monitoring.

• DST55R Strain Sensor
  IP69K-rated strain sensor ideal for outdoor machinery, built for long-term stability in load-bearing structures.

Each of these components contributes to diagnostic coverage (DC), reliability (MTTFD), and architecture redundancy—key factors in building PLd/SIL2-certified machine designs.

Scalable Safety: From Compliance to Certification

Baumer’s approach is modular, allowing engineers to scale system safety based on their project’s lifecycle stage:

1. Compliant Safety
Validated sensor designs and SISTEMA libraries simplify system-level integration and PLd calculations.

2. Certified Safety
TÜV-approved PLd/SIL2 sensors with supporting documentation (PFHd, MTTFD) enable quick certification and global market acceptance.

This dual-level approach gives OEMs flexibility—offering compliance starting points today and full certification pathways tomorrow.

Simplified Integration for OEM Engineers

Baumer provides ready-to-deploy digital tools that cut engineering time:

• Baumer Sensor Suite (BSS) – Configure and diagnose CANopen sensors in one intuitive dashboard.

• SISTEMA Safety Libraries – Preconfigured for quick PL/SIL analysis.

• CODESYS Integration Support – Simplifies PLC communication and field deployment.

• Cybersecurity Guidance – Secures networked communication in connected machine ecosystems.

These tools allow safety engineers to validate sensor integration and streamline the design-to-validation cycle.

Why Baumer Safety Sensors Matter

Functional Safety is no longer just a regulation—it’s a design philosophy that drives reliability, uptime, and trust.

OEMs that adopt Baumer’s PLd/SIL2-certified sensor solutions gain:

• Reduced accident risk and liability

• Easier certification and documentation

• Real-time system visibility

• Future-ready interoperability

By combining precision sensing with proven safety engineering, Baumer helps you build machines that protect operators and elevate performance.

Take the Next Step

Future-proof your mobile machinery with Baumer’s Functional Safety sensors and tools.

Automation Distribution offers complete support for specifying, sourcing, and integrating these advanced Baumer solutions—including GIM600R, EAM580R, PP20S, DST55R, and GCA-series sensors.

Contact us today to explore certified Baumer sensor options tailored to your machine safety architecture.