Industrial Safety
AI-Driven Conveyor Protection & Operational Intelligence for Industry 5.0
Overview
Conveyor belts vary widely across industries—from compact, high-speed packaging conveyors to massive automobile assembly line conveyors stretching hundreds of meters. Despite their differences, all conveyors share one critical requirement: continuous monitoring and instant response to prevent injuries, blockages, and quality issues. Flagman's AI-Powered Conveyor Belt Safety System brings Industry 5.0 intelligence to this entire spectrum. Using synchronized AI cameras, the system protects operators from entrapment hazards, enhances production visibility, and automates quality control across both small conveyors and large-scale automotive assembly conveyors. Whether it's a small material transfer belt or a full vehicle chassis conveyor, Flagman ensures uninterrupted monitoring, intelligent response, and operational excellence.
The Challenge
Conveyors present unique risks due to long-distance material movement, high-speed processing, workers interacting near moving rollers, multi-shift operations, and complex layouts from small conveyors to expansive automotive lines. Key limitations include:
Key Challenges
- Manual supervisors cannot oversee all conveyor sections
- Entrapment can occur in milliseconds
- Pull-cord emergency stops may be out of reach
- Large assembly conveyors span multiple floors & zones
- QC teams struggle to inspect every item in high-speed systems
- Small conveyors are often ignored but pose equal risks
Flagman Solution
Flagman continuously monitors human intrusion near rollers, pinch points, transfer stations, material flow, product counting, defects, and safety zones across all conveyor types. When danger or deviation is detected, Flagman activates audio-visual alerts, sends PLC/relay signals to stop or slow the conveyor, notifies supervisors instantly, logs the event with evidence, and supports automated QC workflows. Flagman enables safer, smarter conveyor operations—no matter the scale.
Key Features
- Human intrusion and entrapment detection near rollers and pinch points
- Emergency stop integration with PLCs and conveyor motor controllers
- Counting, verification, and line balancing for production tracking
- Defect detection and quality inspection without slowing the line
- Multi-zone, multi-line monitoring with independent logic per zone
- Centralized dashboard with safety, QC, and performance analytics
Benefits
Prevent Entrapment Injuries
Real-time detection and automated emergency stops protect workers from entrapment and nip-point injuries across conveyors of all sizes.
Early Detection of Issues
AI identifies jams, defects, and flow issues instantly, enabling proactive intervention before they cause downtime or quality problems.
Operational Visibility at All Scales
Unified monitoring across small packaging conveyors to automotive-scale assembly lines provides complete operational transparency.
Optimized Production Flow
Counting and QC analytics streamline production monitoring, improve quality control, and support line balancing without manual intervention.
Reduced Downtime & Maintenance Costs
Predictive insights and early issue detection minimize unplanned downtime and reduce maintenance expenses across conveyor systems.
Better Investigation Capability
Comprehensive video logs and event tracking with supporting evidence enable quick root cause analysis and incident resolution for audit compliance.
Frequently Asked Questions
Yes — via PLC or relay integration.
Yes — from small conveyors to long assembly lines.
Yes — AI models support counting and defect detection.
Yes — multiple camera nodes enable long-run coverage.
Audio/visual alarms + dashboard + optional mobile alerts.
Yes — full integration supported.
No — works offline for all core safety logic.
Ready to Transform Your Safety Operations?
See how Flagman can help you achieve zero-harm operations with AI-powered safety systems. Our team will show you how this solution fits your specific environment.
