HEXOPUS
Flange-mounted safety system that makes any robot into a human-aware
HEXOPUS is Aura Sensae’s compact safety device designed to transform robotic applications into human-aware collaborative systems.
Mounted between the robot flange and the end-effector, HEXOPUS creates an invisible dynamic safety zone that moves with the robot and monitors human presence in real time. The system focuses on the interaction area itself: the end-effector, the object being handled and the operator working nearby.
Thanks to capacitive sensing and intelligent signal processing, HEXOPUS detects human proximity before contact and enables the robot to slow down, stop or adapt its movement according to the level of risk.
Safety before contact.
Collaboration without unnecessary downtime.
What is HEXOPUS?
HEXOPUS is a smart safety device for Human-Robot Collaboration applications.
Unlike traditional safety systems based on fixed barriers, cages or full machine shutdowns, HEXOPUS creates adaptive safety spaces around the robot’s end-effector. These dynamic zones move with the application and allow the system to react to human presence with graduated and deterministic responses.
The result is a safer collaborative environment where the robot does not simply stop when a person enters the area, but responds intelligently according to the actual proximity and risk level.
Passive protection vs Active awareness
Passive protection
Fixed safety zones
Rigid barriers
Full-cell shutdowns
Cycle time losses
Limited collaboration
Reaction after risk or contact
Active awareness
Pre-contact human detection
Dynamic safety areas
Graduated robot responses
Shared workspaces
Cycle time protection
Human-aware robotic applications
Detection Distance
2000 mm
1-50-4-M6 compatible
ISO 9409
ISO 13849
PL-d CAT 3
IEC 61508
SIL 2
Key features
Real-time human detection
HEXOPUS detects human presence near the robot application in real time, helping the system react before physical contact occurs.
Dynamic safety zone
The safety area moves with the robot and adapts to the position of the end-effector, creating protection exactly where interaction happens.
Human-object discrimination
The system is designed to distinguish operators from surrounding objects, reducing unnecessary stops and improving operational efficiency.
Up to 2000 mm detection range
The detection range can be configured according to the application and the working environment, with coverage up to 2000 mm.
Functional safety
HEXOPUS targets key industrial safety requirements, including SIL 2 and PL-d applications.
Industrial integration
HEXOPUS supports industrial interfaces such as CAN bus, OSSD and FSoE, and is designed for integration into both new robotic cells and existing systems.
Key features
Real-time human detection
HEXOPUS detects human presence near the robot application in real time, helping the system react before physical contact occurs.
Dynamic safety zone
The safety area moves with the robot and adapts to the position of the end-effector, creating protection exactly where interaction happens.
Human-object discrimination
The system is designed to distinguish operators from surrounding objects, reducing unnecessary stops and improving operational efficiency.
Up to 2000 mm detection range
The detection range can be configured according to the application and the working environment, with coverage up to 2000 mm.
Functional safety
HEXOPUS targets key industrial safety requirements, including SIL 2 and PL-d applications.
Industrial integration
HEXOPUS supports industrial interfaces such as CAN bus, OSSD and FSoE, and is designed for integration into both new robotic cells and existing systems.
Why HEXOPUS?
Safety without sacrificing productivity
Traditional safety approaches often force a trade-off: protect people by stopping the machine, or preserve productivity by limiting human access to the robotic area.
HEXOPUS helps overcome this trade-off. Instead of relying only on fixed safety zones or full shutdowns, HEXOPUS enables a more flexible response. The robot can adapt its behavior according to human proximity, supporting safer interaction while reducing unnecessary interruptions.
Human detection
HEXOPUS is designed to detect human presence around the robot application before contact occurs.
By distinguishing operators from surrounding objects, the system enables the robot to react intelligently to proximity, supporting safer collaboration without unnecessary interruptions.
HEXOPUS vs traditional safety systems
Traditional safety systems often depend on line of sight, fixed areas or contact-based detection. They can be difficult to adapt to existing layouts and may require significant redesign of the production cell.
HEXOPUS adds a new layer of human-aware sensing directly to the robotic application. It provides volumetric, pre-contact detection around the end-effector, with a 360° approach that does not depend on a fixed external perimeter. This makes it particularly suitable for collaborative environments, assembly lines, material handling and robot automation cells where flexibility and continuity are essential.
Designed for Industry 4.0 environments
Manufacturing environments are becoming more flexible, automated and collaborative. Robots are no longer isolated machines working behind cages: they increasingly operate close to people, tools and products.
This requires safety systems that can understand proximity, context and movement in real time. HEXOPUS brings awareness to industrial robotics, helping robotic systems detect, understand and react to human presence before contact occurs.
Applications
HEXOPUS is designed for industrial scenarios where people and robots share the same operational space, including:
Human-Robot Collaboration applications
Robotic assembly lines
Material handling systems
End-effector safety applications
Robot automation cells
Legacy robotic systems requiring safety upgrades
Flexible production environments
A new standard for collaborative safety
HEXOPUS does more than protect the robot.
It protects the interaction.
By focusing on the end-effector and the object being handled, HEXOPUS helps make the application itself collaborative, not just the robot.
A compact, intelligent and responsive safety device for companies that want to increase collaboration without compromising operator protection or industrial productivity.
Bring human-aware safety to your robotic applications
HEXOPUS is designed for companies that want to make robotic cells safer, more flexible and truly collaborative.
If you are working on a new automation project, upgrading an existing robotic system or looking for a smarter alternative to traditional safety barriers, Aura Sensae can help you evaluate the best integration approach.
Fill out the form to get in touch with our team and discover how HEXOPUS can bring safety before contact to your industrial environment.
Comments are closed.