Suzlon Energy Limited
Solution Provided: Person Detection, Hard Hat detection using AI CCTV
Case Study: AI CCTV for PPE Compliance and Restricted Area Monitoring
Customer: Suzlon Energy Limited
Location: S. No. 42/2–3, 54/1–8, Bhensnlore, Near Checkpost, Village Denutha, Daman and Diu – 39621
Solution Provider: Sara Electronics Security Pvt. Ltd.
Customer Requirement
Suzlon Energy Limited required automated monitoring of designated production areas to identify personnel entering without mandatory personal protective equipment (PPE), including hard hats, and detect entry into restricted machine zones.
The requirement included audible warnings and integration with machine controls to initiate shutdown when a configured violation occurred.
Solution Provided
Sara Electronics Security Pvt. Ltd. deployed five CCTV cameras integrated with AI video analytics, covering different operational areas.
| Camera | Monitoring Function | Event Detected |
|---|---|---|
| Camera 1 | PPE and hard hat compliance | Person entering the designated zone without required PPE or a hard hat |
| Camera 4 | PPE and hard hat compliance | Person entering the designated zone without required PPE or a hard hat |
| Camera 2 | Restricted area monitoring | Person entering a defined restricted zone |
| Camera 3 | Restricted area monitoring | Person entering a defined restricted zone |
| Camera 5 | Restricted area monitoring | Person entering a defined restricted zone |
AI Monitoring and Detection
Virtual detection zones were configured within each camera’s field of view. AI analytics monitored personnel within these zones and generated events for the relevant PPE violation or restricted area entry.
Automatic Voice Announcements
An IP speaker was integrated to play prerecorded announcements when a configured event was detected. These announcements warned personnel about the violation and prompted corrective action, such as wearing the required PPE or leaving the restricted area.
Machine Shutdown Integration
The camera’s potential-free I/O output was connected to the machine’s power control circuit through the appropriate control interface. When a configured event occurred, the output initiated a machine shutdown command.
The potential-free contact serves as a control signal; it does not directly switch the machine’s power load. AI detection supports site safety procedures, while any safety-critical shutdown function requires an appropriately engineered and validated machine safety circuit.
Operating Sequence
A person enters a camera’s configured monitoring zone.
AI analytics checks for the relevant PPE violation or restricted area entry.
On detecting a configured violation, the system triggers a prerecorded announcement through the IP speaker.
The camera’s potential-free output activates the connected machine shutdown interface according to the configured event logic.
Operational Benefits
Continuous monitoring: Automated observation of five designated areas.
Improved PPE supervision: Detection of personnel entering monitored zones without required PPE or hard hats.
Restricted zone alerts: Identification of human entry into defined machine hazard areas.
Immediate audible intervention: Prerecorded warnings delivered near the monitored area.
Integrated machine response: Detection events linked to the machine shutdown control interface.
Support for safety teams: Additional monitoring to complement physical safeguards, supervision, and operating procedures.
Project Outcome
The deployment brought together AI CCTV detection, audible warnings, and machine control integration across five monitoring areas at Suzlon Energy Limited’s Daman facility.
The case demonstrates how video analytics can support industrial safety by identifying defined violations and triggering a coordinated response. Quantified improvements in compliance, response time, or incident reduction would require post-installation operating data.