As the industrial manufacturing sector advances toward digitalization, workplace safety remains the critical baseline for corporate survival. While traditional “Lockout/Tagout” procedures effectively isolate hazardous energy through physical means, their practical implementation often presents persistent management challenges for factories—specifically, accidents resulting from human error, unauthorized tag placement, or incomplete tag removal. Established in 2004 and backed by two decades of dedicated research and development in visual algorithms, New Auto Element Co., Ltd.—a recognized National High-Tech Enterprise—is leveraging its extensive expertise in facial recognition systems and AI edge computing to provide modern manufacturing facilities with a highly reliable electronic lockout/Tagout Systems.
Two Decades of Accumulated Expertise in Vision Algorithms: The Technical Foundation for Safety Management
Advantages and Applications of Electronic Lockout/Tagout Systems
At the core of factory automation management lies the pursuit of “determinism.” Since its inception in 2004, Cheyuansu has positioned the research and development of vision algorithms as the driving force behind its corporate growth. In factory production environments—where complex conditions such as intense lighting, smoke, or insufficient illumination often prevail—conventional recognition devices frequently struggle to maintain a consistent recognition rate. Cheyuansu’s facial recognition system, however, leverages high-precision algorithms honed over two decades—combined with dual-camera liveness detection technology—to ensure accurate, sub-second recognition across a wide range of demanding industrial settings. This capability not only accelerates access control and entry procedures but also provides the most robust foundation for identity verification within critical factory tag-out/lock-out protocols.
Electronic Safety Tagging: Embedding Biometrics into Power Control Logic
Traditional safety tagging workflows rely on paper records or physical tags, resulting in low management efficiency and a lack of real-time monitoring capabilities. In contrast, innovative facial recognition access control solutions utilize relay signal linkages to deeply integrate the identity of the “person” with the power supply of the “machine,” thereby realizing a truly electronic safety tagging system.
Automated Lockout-Tagout: Identification Triggers Immediate Shutdown
When technicians require access to active equipment zones for routine maintenance or troubleshooting, the process begins at the pedestrian access turnstiles situated at the perimeter of the isolation zone. Employees authenticate their identity via a facial recognition terminal, where an AI edge computing unit instantly verifies their credentials. Upon successful identification, the system automatically generates a “Lockout-Tagout” record within the management platform and simultaneously transmits a relay signal to the central control console.
At this juncture, a critical physical interlock sequence is initiated: upon receiving the signal, the central control console immediately cuts off the power supply to the corresponding equipment zone, thereby ensuring that the maintenance environment remains in a de-energized, safe state. Concurrently, on-site audible and visual alarms activate to provide dual alerts—both visual and auditory—notifying surrounding personnel that the specific zone has been locked out and tagged by a designated individual. This automated logic, powered by the facial recognition system, effectively eliminates the risk of accidental re-energization caused by communication breakdowns.
Precision Tag Removal: The Safety Safeguard for “Zero Personnel” Verification
The process of re-energizing equipment following maintenance is the phase presenting the highest safety risks. The solution designed by Cheyuansu places strong emphasis on a “closed-loop logic” for verifying the complete clearance of personnel. Upon exiting the work zone, maintenance personnel are required to undergo a second facial recognition scan to complete the “tag removal” procedure.
For large-scale maintenance projects involving multi-person collaboration, the system’s backend features intelligent headcount tracking and logical matching capabilities. The system determines that the area is free of any lingering personnel only after every individual registered as having entered has successfully completed their tag removal verification. At this point, the facial recognition access control system issues the final relay signal to restore power; the equipment powers up and resumes operation, and the audible and visual alarms are deactivated. This fully digitized management approach—spanning the entire cycle from entry tagging to exit tag removal—significantly elevates both the level of intelligence and the overall quality of management within the facility.
Technical Advantages of the Electronic Safety Tagging Solution
Compared to traditional methods, the solution provided by Cheyuansu—which integrates pedestrian turnstiles with AI edge computing—offers the following distinct advantages:
High-Precision Recognition and Security: Utilizing cutting-edge AI large-model vision algorithms, the system supports facial recognition even when subjects are wearing masks, and features liveness detection to prevent spoofing attempts using photos or videos, thereby ensuring the unique identity of the individual performing the safety tagging.
Real-time Monitoring and Alarm System: The management system provides real-time monitoring of the status of all turnstiles and electronic safety locks. In the event of an unauthorized forced entry or if maintenance operations exceed the allotted time limit, the AI-driven alarm system immediately captures video footage and issues an alert.
Industrial-Grade Hardware Stability: The pedestrian turnstiles are constructed from SUS304 stainless steel, while the facial recognition terminals feature high-level ingress protection (IP ratings) against water and dust, ensuring the system meets the demands of continuous, 24-hour factory operations.
Data Analysis and Process Optimization: The system automatically records a history of all operations, generating detailed reports that assist factory management in analyzing equipment maintenance cycles and forecasting potential production risks.
Proven Capabilities Across Diverse Industries
Cheyuansu’s expertise in visual algorithms extends far beyond factory automation management; it has found widespread application in numerous sectors, including smart campuses, smart eldercare facilities, and big data platforms for transportation fleets. From our deep collaborations with PICC and Ping An Insurance—initiated in 2019—to the launch of our Smart Campus Management Platform in 2023, the company has remained steadfast in its commitment to leveraging visual technology to resolve real-world safety and management challenges.
Within the factory environment, we fully recognize that every relay signal carries implications for the safety and well-being of the workforce. Consequently, prior to leaving our facility, every piece of our equipment undergoes rigorous stress testing and environmental simulation. This ensures that, even in the face of voltage fluctuations or sudden power outages, our devices unfailingly maintain their pre-configured safety states—such as automatically opening access gates in the event of a power failure, in compliance with fire safety regulations.
If you are seeking to enhance the quality of safety and access management within your factory premises, or if you wish to digitize your production line’s safety lockout/tagout procedures through a customized facial recognition access control solution, Cheyuansu’s 20 years of industry experience stand ready to serve as your most reliable foundation.
FAQ: Technical Q&A on Electronic Lockout/Tagout (LOTO) Systems for Factories
How does the electronic safety tagging system integrate with a factory’s existing PLC system?
Cheyuansu’s facial recognition system and AI edge computing terminals support standard relay outputs, the Wiegand protocol, and TCP/IP-based API interfaces. Through these industry-standard interfaces, physical-level signal linkage can be easily established with the factory’s PLCs or central control consoles.
During maintenance operations, if the equipment suddenly loses network connectivity, will the safety logic still remain active?
Since our terminals are equipped with powerful AI edge computing capabilities, both identity verification and signal linkage logic are executed locally on the device. Even if temporarily disconnected from the server network, the facial recognition access control unit can still execute lockout and tagout operations based on its local authorization database, ensuring that safety protocols remain unaffected by network fluctuations.
How does this system support mobile-based management?
Employees and management personnel can monitor the real-time lockout status of equipment via a dedicated mobile application. Managers can receive notifications regarding lockout/tagout events and anomaly alerts directly on their mobile phones, and even remotely assist with authorization in emergency situations—thereby significantly reducing response times.
Is the system’s storage capacity sufficient to support large-scale factories?
Our high-performance terminals support the local storage of over 50,000 facial templates and millions of access logs, fully meeting the comprehensive personnel management requirements of large-scale industrial complexes
Conclusion
From our initial explorations into vision algorithms in 2004 to our 2026 facial recognition systems—now deeply integrated into industrial automation—Cheyuansu Industrial Co., Ltd. has consistently remained at the forefront of technological application. By seamlessly integrating pedestrian turnstiles with innovative electronic safety lockout-tagout procedures, we provide factories with more than just a set of tools; we deliver a comprehensive security philosophy grounded in biometric technology and automated logic.
In this new era of intelligent manufacturing, security stands as the ultimate driver of productivity. To choose Cheyuansu is to choose the assurance of professional expertise—the culmination of two decades of dedicated experience.
External Authoritative References:https://www.nist.gov/programs-projects/face-recognition-vendor-test-frvt
