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Case Study

Food Processing Band Saw

Food processing band saws are extremely dangerous to operate. There are hundreds of amputation cases annually due to how dangerous it is to work so close to an open blade.  Our customer and RSI worked together to develop a system that could detect when an operator’s hand or fingers were too close to the blade and stop the blade in order to prevent an accident.



Compay Name: Private

Date: Private

Website: Private




Services Provided by RSI

Hardware Selection – RSI assisted with the selection of the servo system including the motor, drive, and gearhead to achieve the fastest stop time for the application budget. An IP69k servo motor was selected due to the washdown environment and the servo drive had to be rated for harsh environments.

Application Software and HMI Development – RSI developed an intuitive touchscreen based user interface; enabling operators to startup quickly and maintenence staff to identify and resolve problems with minimal downtime.
The application we developed logs relevant data to an online server for remote diagnostics and data analytics. The data is analyzed alongside other installed machines to determine if a machine is in need of maintenance. The data is also used to identify operators in need of further training which improves worker efficiency.

Vision System Development – RSI developed the vision system that detects the presence of an operator’s hand to trigger a fast stop before the operator even touches the blade. The vision system is seamlessly integrated with the main user interface that handles all the motion, setup, and configuration.

User Interface

Status Tab

Allows operators to see the current state of the equipment so they can make adjustments as needed.

Analytics Tab

Allows operators to view a number of indicators that are useful for different situations.

Faults Tab

Displays a history of the system faults, drive faults, and drive warnings for faster troubleshooting.

Admin Tab

This tab is password protected so authorized users can change operation modes, configure settings, and setup the machine.

Solution Technologies

  • RSI Custom Vision System
  • RSI Custom Designed RapidSaw HMI
  • sRMP EtherCAT Motion Controller
  • IP69K Washdown Servo Motor
  • EtherCAT Servo Drive

Customer Benefits

  • Significantly improved safety for operators.
  • Intuitive HMI which is integrated with Vision system for quickly identifying and resolving problems.
  • Remote diagnostics.
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