Reducing Nuisance Stops in Collaborative Cells

Legacy safety system functionality is limited in dynamic environments

Nuisance stops kill throughput and frustrate operators. They also create a dangerous pattern: people start working around safety systems because they don’t trust them to behave predictably.

Most nuisance stops come from one of three issues:

1. The sensing method can’t interpret the full workspace

2. Zones don’t match how people actually move

3. The system can’t distinguish real risk from normal activity

SR-1 reduces nuisance stops by modeling the environment in 3D with redundant sensing. Instead of triggering safety behavior based on a narrow view, SR-1 bases behavior on what’s actually present in the workspace. That lets you design zones and behaviors that map to real tasks such as material staging, inspection points, operator paths, without opening gaps.

What changes when you tune for reality:

• You set zones around the hazard, not around a single sensor’s limitations

• You reduce false triggers caused by partial views and occlusions

• You keep safety behavior consistent across changeovers

You still need a disciplined process:

• Confirm stop time and behavior at commissioning

• Document zone intent and assumptions

• Validate after tooling or layout changes

If your cell “stops all the time,” don’t blame the operators. Fix the design.

Request a demo. We’ll review your top nuisance-stop drivers and show how SR-1 handles them.