Boosting industrial safety with real-time FPGA-based image analysis and network security

By Srinivas Shekar, CEO and Co-founder, Pantherun Technologies

In an industrial setting, safety is crucial, with several hazards that must be constantly monitored to avoid accidents. An FPGA-based image analysis system improves safety by providing real-time monitoring and rapid response. It integrates secure Layer 2 and Layer 3 network functionalities directly onto the FPGA, providing uninterrupted, low-latency connectivity and robust data security. This design reduces the board’s bill of materials (BOM) by eliminating the need for external network controllers.

Advanced safety monitoring in manufacturing plants
An advanced safety monitoring system is implemented in a major manufacturing plant to supervise high-risk locations like assembly lines, storage of hazardous materials, and machinery. The system does real-time picture processing, identifying potentially dangerous situations and mishaps, using high-definition cameras and FPGAs. Because there is no longer a need for a separate network controller on the board, the integration of Layer 2 and Layer 3 network functions directly on the FPGA improves system performance and security while lowering equipment costs.

Real-time image analysis and secure data transmission
High-definition cameras are placed to capture continuous video feeds of critical areas. These video streams are then transmitted to an FPGA-based image analysis system, which processes the data in real-time to identify safety breaches, equipment malfunctions, and unauthorized personnel. The processed data is packetized on the FPGA, incorporating Layer 2 functions like frame encapsulation, QoS, Ring protocols, VLAN, and error detection.

The FPGA manages Layer 3 functions, routing packets containing alerts and processed data to relevant safety systems or personnel based on IP addresses. It secures AES-encrypted data transmission using onboard cryptographic capabilities and ensures protection from potential breaches without latency. Immediate alerts and responses are triggered for detected safety issues, routed through the network to safety officers, emergency systems, and shutdown controls.

Comprehensive benefits for industrial safety
An FPGA-based image analysis system with integrated secure Layer 2 and Layer 3 network functions and AES-based encryption offers a comprehensive solution for enhancing safety in industrial environments. This system provides real-time monitoring, rapid hazard detection, and secure AES-encrypted communication, helping to prevent accidents and ensuring a safer workplace. It minimizes latency, enhances security, and reduces infrastructure costs by eliminating the need for separate networking hardware. The system’s scalability and flexibility allow for easy expansion to monitor additional areas or integrate new safety protocols and detection algorithms.
Utilizing FPGA technology helps businesses safeguard employees, save downtime, and prevent accidents. This cutting-edge safety monitoring system encourages a proactive approach to danger management in addition to guaranteeing adherence to safety requirements. It contributes to the upkeep of a safe and effective operation, which eventually results in an industrial environment that is more resilient and fruitful.