Door switch systems are fundamental machine safety components used in industrial facilities to secure access to machines and production areas, prevent unauthorized or uncontrolled entry into hazardous zones, and minimize occupational accidents. In robotic cells, presses, CNC machines, packaging lines, and high-speed automation systems, door switches are among the indispensable elements of safe production.

In modern industry, production speeds have increased and machines have become more complex and powerful. These developments have also brought increased occupational safety risks. Physical protective doors and fences alone are no longer sufficient; these access points must be monitored in a controlled and safe manner. Door switch systems address this need by directly linking the status of the door to the operating state of the machine.

At Körfeztek Technology, we approach door switch systems not merely as simple on–off devices, but as integral parts of a comprehensive machine safety concept that includes automation integration and regulatory compliance. We provide process-specific, long-lasting door switch solutions that comply with international safety standards.

What Is a Door Switch?

A door switch (safety door switch) is a safety device that detects whether a protective door, cover, or guard is open or closed and, based on this information, allows or prevents machine operation. When the door is opened, the system automatically stops the machine or switches it to a safe mode, and does not allow the machine to restart until the door is properly closed.

Main purposes of door switch systems:

• Controlling access to hazardous areas

• Ensuring safe human–machine interaction

• Preventing uncontrolled machine operation

• Reducing occupational accidents and equipment damage

Importance of Door Switch Systems in Industry

A significant portion of industrial accidents occur when workers access moving or hazardous machine parts, especially during maintenance, adjustment, or intervention. Door switch systems eliminate these risks systematically and automatically.

Key benefits for industrial facilities:

• Prevention of occupational accidents

• Increased employee safety

• Full compliance with legal requirements and standards

• Protection of machines and equipment

• Reduction of operator errors

• Safe and controlled production

These advantages make door switch systems a cornerstone of modern machine safety.

Application Areas of Door Switch Systems

Door switch systems are used in all industrial applications where access to hazardous areas must be controlled.

Main application areas:

• Robotic production cells

• Press and cutting machines

• CNC machines and machining centers

• Packaging and palletizing lines

• Conveyor and transfer systems

• Automated assembly lines

• Warehousing and intralogistics areas

Each application is configured specifically based on risk analysis and machine structure.

Operating Principle of Door Switch Systems

Door switch systems detect whether a door is open or closed and transmit this information to a safety relay or safety PLC. If the door is not securely closed, the system does not allow machine operation.

Basic operating steps:

• Door closed → switch is active

• Safety circuit is closed

• Machine operation is permitted

• Door opened → switch status changes

• Safety circuit is interrupted

• Machine stops or enters safe mode

This entire process occurs within milliseconds.

Types of Door Switches

Door switch systems are designed in various types depending on safety level and application requirements.

Mechanical Door Switches

Classic systems that operate through physical contact with the door. Preferred for simple applications.

Magnetic Door Switches

Provide contactless detection using a magnet mounted on the door. Offer longer service life and higher durability.

Coded (RFID) Door Switches

Each switch–actuator pair has a unique code, providing high protection against bypassing and manipulation.

Locked Door Switches (Interlocks)

Do not allow the door to open until the machine has completely stopped. Used in high-risk applications.

Locked Door Switch Systems

Locked door switches allow the door to be opened only when safe conditions are met. They are critical for robotic cells and high-energy machines.

These systems ensure that:

• The door cannot be opened prematurely

• Access is not possible before the machine stops

• The door remains locked until hazardous movements are completed

This structure provides maximum safety.

Main Components of Door Switch Systems

An effective door switch system requires coordinated operation of hardware and control components.

• Door Switch Unit: The main safety element that detects door status

• Actuator / Magnet / Coded Element: The counterpart mounted on the door

• Safety Relay or Safety PLC: Evaluates signals and controls the machine

• Mechanical Mounting Components: Ensure proper alignment and stable installation

Door Switches and Machine Safety Standards

Door switch systems must be designed in accordance with international machine safety standards.

Key standards include:

• EN ISO 14119 (Safety-related interlocking devices)

• EN ISO 13849-1 / 13849-2

• IEC 61508

• EN 62061

Körfeztek Technology bases all door switch projects on these standards to deliver safe and compliant solutions.

Use of Door Switches in Robotic Cells

In robotic cells, door switches control access to the cell and ensure safe robot operation.

This enables:

• Robot stop when the door is opened

• Operator safety

• Full compatibility with physical fencing systems

Door Switches in Conveyor and Line Systems

In conveyor and transfer systems, door switches secure maintenance and intervention points.

In these applications:

• The line is stopped during intervention

• Unauthorized access is prevented

• Maintenance safety is increased

Productivity and Operational Advantages

Door switch systems provide not only safety, but also operational efficiency.

Main advantages:

• Controlled downtime

• Safer maintenance processes

• Reduced failures and damage

• Production continuity

Digitalization and Industry 4.0 Integration

Door switch systems can serve as valuable safety data sources in digital factory and Industry 4.0 projects.

They enable:

• Door open/close logs

• Safety violation reports

• Maintenance and usage analysis

Project Management and Commissioning

The success of door switch systems depends on proper engineering and disciplined project management.

Körfeztek Technology applies the following steps meticulously:

• Risk analysis and safety concept development

• Selection of appropriate door switch systems

• Mechanical and electrical integration

• Safety PLC integration

• Testing, validation, and training

After-Sales Support and Sustainability

The reliability of door switch systems is ensured through regular inspection and maintenance.

Services provided:

• Periodic testing and validation

• Adjustment and alignment checks

• Technical support and consultancy

• Support for safety audits

Future Trends in Door Switch Systems

Coded and RFID-based systems, remote monitoring, intelligent manipulation detection, and advanced safety PLC integration are shaping the future of door switch technology. Systems are evolving from simple door monitoring solutions into structures that analyze risks and provide preventive safety.

Why Körfeztek Technology?

Key reasons to choose Körfeztek Technology for door switch systems:

• Extensive experience in machine safety and automation

• Expertise in international safety standards

• Process-specific engineering solutions

• Advanced safety PLC and automation integration

• Strong project management

• Long-term partnership approach

Körfeztek Technology is not merely an equipment supplier, but a strategic solution partner that designs safe production environments.

Conclusion

Door switch systems are a fundamental element of occupational safety, machine protection, and regulatory compliance in modern industrial facilities. Properly designed and integrated door switch solutions protect employees while supporting production continuity.

With its holistic approach to door switch systems, Körfeztek Technology strengthens the safe and sustainable production infrastructures of industrial enterprises. To control access to hazardous areas and create safe working environments, you can benefit from Körfeztek Technology’s expertise.