Industrial Safety Intelligence – Real-Time Vehicle and Human Speed Monitoring with AI
The Context
Industrial plants often involve continuous movement of vehicles and personnel within shared zones. Ensuring safety compliance, preventing accidents, and maintaining optimal traffic flow are critical. Traditional monitoring systems based on manual observation or basic sensors often result in blind spots and delayed responses.
To address these challenges, a comprehensive AI-powered surveillance and analytics platform was designed, capable of detecting and reporting overspeed incidents, human intrusions, and safety policy violations across an entire industrial layout.
The Challenge
- Manual surveillance methods were insufficient for large plant areas and highspeed zones.
- Speed violations by internal and external vehicles posed significant safety risks.
- Human entry into restricted or dangerous zones required real-time detection and
- The system needed to integrate with high-resolution RTSP IP cameras and operate with minimal latency.
Alerts and analytics had to be delivered without disrupting existing IT infrastructure or plant
Our Solution
PrimeMover Solutions developed a robust AI-driven video analytics system designed for real-time vehicle speed tracking and human detection within industrial environments. The platform supports the full spectrum of safety use cases through modular, edge-compatible components and seamless integration capabilities.
Core technologies include YOLO-based object detection, perspective-transformed speed estimation, polygonal zone filtering, and live notification engines. The system functions autonomously and offers live monitoring via an embedded FastAPI and WebSocket-enabled interface.
Key Features of the Safety Intelligence System
Real-Time Speed Estimation
Measures precise vehicle speed using calibrated pixel-to-distance transformation from live video feeds.
Human Detection & Safety Violation Alerts
Instantly flags unauthorized human presence in restricted or high-risk operational areas.
Multi-Object Tracking
Simultaneously tracks multiple vehicles and individuals with unique ID overlays across frames.
Zone-Based Compliance Monitoring
Custom polygon zones enforce area-specific rules such as speed limits or human-only access zones.
Live Monitoring Dashboard
Displays real-time annotated video streams and provides access to event logs, violation reports, and analytics.
Automated Email & SMS Alerts
Sends instant alerts with snapshot evidence and data tables showing vehicle ID, type, speed, and timestamp.
Smart Event Classification
Supports breach classification by severity (color-coded: Green, Orange, Red) with incident history.
Data Retention and Audit Trails
Stores event footage, logs, and violation records securely for up to two years to support audit, compliance, and insurance processes.
Fleet and Traffic Flow Insights
Monitors vehicle congestion, frequent stoppages, and predicts bottlenecks for route optimization.
Full-Coverage Deployment
System deployed across straight and curved roads, loading zones, and high-traffic areas with seamless scaling.
Impact & Result
By implementing this real-time AI monitoring system, the plant achieved:
- More than 90% accuracy in speed and human detection with high FPS camera
- Zero manual intervention in safety policy enforcement.
- Proactive safety compliance through continuous real-time surveillance and automated alerts.
- Data-driven decision making for traffic management, zone planning, and safety
- Scalable infrastructure supporting full facility expansion without redesign.
Conclusion
PrimeMover Solutions remains at the forefront of AI-powered video intelligence, enabling smarter, safer, and more efficient industrial ecosystems. This end-to-end solution for vehicle and human speed monitoring demonstrates our commitment to blending cutting-edge vision AI, intelligent automation, and practical safety enforcement in industrial settings.
Our unified platform now delivers complete coverage, from detecting speed violations and human intrusions to providing live dashboards, automated alerts, and long-term data insights, ensuring a safer and smarter plant environment.
