VISIONSAFETYAI  /  Industrial Restricted Zone Detection

PLC & SCADA Compatible

visionsafetyai@gmail.com

Technical Overview

From Camera To Safe Stop In Under 200ms

A complete technical walkthrough of the SentinelAI detection pipeline — from video capture to PLC emergency stop signal, with no human in the loop.

01

Industrial IP Camera Captures the Zone

CONTINUOUS 24/7 VIDEO SURVEILLANCE

An IP66/IP67-rated industrial camera with built-in IR illumination is mounted at the optimal angle to cover the complete restricted zone. The camera streams 1080p video continuously to the detection system via the local plant network using RTSP protocol.

Multiple cameras can cover a single large zone, or each camera can protect a separate zone. The system supports up to 16 simultaneous camera feeds per detection server.

1080p / 4MP optionsIP66/IP67 ratedBuilt-in IR illuminationRTSP streamUp to 16 cameras per server
02

AI Detection Engine Processes Every Frame

ON-SITE GPU — NO CLOUD — FULLY AIR-GAPPED

An on-site industrial PC with a dedicated GPU runs our proprietary AI detection engine at 60–100 frames per second. Every frame is analyzed for human presence within the configured Region of Interest (ROI) — a polygon that precisely defines the danger boundary.

Detection runs entirely on your local network. No internet connection is required. No data leaves the plant.

60–100 FPS detectionProprietary AI modelPolygon ROI per cameraGPU acceleratedFully air-gapped99.4% accuracy
03

3-Frame Confirmation Eliminates False Stops

INTELLIGENT FALSE-POSITIVE SUPPRESSION

A single-frame detection does not trigger the E-STOP. The system requires a human to appear in the ROI in three consecutive frames before sending any signal. This eliminates false triggers from birds, falling debris, dust clouds, and momentary image artifacts common in industrial environments.

Response time breakdown

Camera frame capture
~16ms
AI detection × 3 frames
~50ms
Relay / PLC signal dispatch
~20ms
PLC scan + relay actuation
~15ms
Total system response time
<200ms
04

PLC / Relay Receives E-STOP Signal

ANY PLC · DRY CONTACT · MODBUS · PROFINET · OPC-UA

The detection system signals the emergency stop through your choice of integration method. The universal method — a normally-closed dry contact relay — wires directly into any existing E-STOP circuit and works with every PLC ever manufactured.

NC dry contact relay (universal)Modbus TCPPROFINET IOEtherNet/IPOPC-UASCADA compatible
05

Machine Stops. Event is Logged.

FULL AUDIT TRAIL FOR SAFETY COMPLIANCE

The machine stops within its normal safety stop sequence. Every detection event is logged with timestamp, zone ID, camera feed, and detection confidence. Logs are stored locally and accessible via the web dashboard and OPC-UA.

Full incident logWeb dashboardLocal storage — no cloudCSV export for auditsEmail / SMS alert option

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