Industrial Safety System Contact
The line The Stop Pull the plug Subsystems Team Contact Employee login

A conveyor that knows when to stop.

Edge AI watches the belt. A Delta PLC decides. A hardwired circuit protects people even if all software fails.

Watch it stop Pull the plug

It sees.

A camera over the belt feeds a Jetson at the edge. It checks every worker for a hardhat, a hi-vis vest and eye protection.

Jetson Orin Nano, PPE detection on the device

It senses.

Gas, temperature, vibration and motor current are read beside the belt. They catch what a camera cannot see.

Readings shown are illustrative

It thinks.

Every signal collapses into one risk index from 0 to 100. Yellow light at 40, buzzer at 70, stop request at 85.

D102, thresholds are placeholders until calibration

It acts.

Only the Delta AS228P switches the conveyor. The AI sends requests. The PLC decides, then drives the K3 run contactor.

Y0.0 drives K3, wired in series with the safety contactor

It protects.

E-stop, light curtain and guard interlock feed a safety relay that cuts motor power directly. No software sits in that loop.

Works with every computer switched off

The Stop.

Risk index, register D102

As the risk index rises from 12, the yellow light comes on at 40 and the buzzer pulses at 70. At 85 the PLC stops the line and records stop code 5.

The Stop.

  1. 12

    Running. Green light, K3 closed.

  2. 72

    Yellow light from 40, buzzer from 70. Still running.

  3. 85

    Stopped. In one scan. The PLC drops K3 and records stop code 5.

Thresholds are placeholders until calibration.

Pull the plug.

The Jetson proves it is alive with a 1 Hz square wave wired into PLC input X0.5 through an opto-isolator. Not over the network.

Cut it. After 2.0 s without an edge the PLC latches a fault and stops the line. It never restarts by itself: it needs 3.0 s of healthy heartbeat, a manual RESET, then START.

The real PLC program, translated line for line to JavaScript

X0.5 Jetson heartbeat, 1 Hz Running
Watchdog T1, 2.0 s
2.0 s
K3, Y0.0
Closed
Fault, M20
Clear
Stop code, D122
0

    The whole loop, live.

    Field, cabinet and operator, in one drawing. Six scenarios, each following the PLC program's real rules. Illustrative only, not plant data.

    FIELD CONTROL CABINET OPERATOR CAMERA GAS TEMP VIBRATION CURRENT SENSORS HARDHAT NO HARDHAT VEST EYEWEAR CONVEYOR E-STOP STACK LIGHT JETSON PPE + RISK INDEX SWITCH PI 5 GATEWAY MQTT IN, MODBUS TCP OUT OPTO RUN FAULT X Y PLC AS228P ONLY OUTPUT AUTHORITY K3 KS SAFETY RELAY X0.5 HEARTBEAT, 1 HZ WATCHDOG HEALTHY Edges every 500 ms RISK INDEX D102 12 40 70 85 Line running Shift started DASHBOARD VIEW AND REQUESTS ONLY START STOP RESET KEY LOCAL / REMOTE LOCAL CONTROLS
    Scenario 1 of 6

    Running

    Vision
    Sensors
    Risk index
    Line, K3
    Heartbeat
    Stop code

    Six subsystems. One authority.

    Industrial control

    The Delta AS228P is the only device allowed to switch the conveyor. A hardwired safety path sits underneath it.

    X0.5, D122, Y0.0 to Y0.6

    Decision AI

    One risk index from 0 to 100. The Jetson computes it. The PLC acts on it.

    Placeholder thresholds

    Computer vision

    PPE detection on a Jetson beside the line. No cloud round trip.

    Hardhat, vest, eyewear

    Connected architecture

    Five layers. Networks carry information, never protection.

    MQTT, Modbus TCP, OPC UA

    Industrial sensing

    What a camera cannot see.

    Gas, temp, vibration, current

    Operational dashboard

    Remote view and requests. Grey until something is wrong.

    ISA-101 screens, ISA-18.2 alarms

    Tested before it touched a motor.

    The PLC program ran on Delta's AS200 simulator in ISPSoft 3.24 on 1 Oct 2026. Nine tests passed and one was not run.

    2.0s

    No heartbeat edge, fault latched, line stops.

    3.0s

    Healthy heartbeat needed before RESET works.

    2.0s

    Audible warning after START, before the belt moves.

    5s

    Gateway silent: alarm only, line keeps running.

    100ms

    PLC timer base.

    Built by five engineers.

    Senior design, EEEN 4393, Prince Mohammad bin Fahd University. A laboratory demonstrator on a 24 VDC conveyor.

    • Abdullah AlhamadiTeam leader, edge AI and system architecture
    • Ahmed AlnasserPLC control and industrial automation
    • Ahmed AlghamdiRaspberry Pi gateway and dashboard
    • Ali AlghanimSensors and field instrumentation
    • Talal Al-MubarkiNetworking and communication

    Advisor Mr. Ahmed Abul Hussain. Co-advisor Dr. Hirenkumar Mewada. Instructor Dr. Samir El-Nakla.

    Talk to the team.