In large-scale construction and infrastructure projects, maintaining jobsite safety while ensuring operational efficiency remains a major challenge.

This case study highlights how a U.S.-based equipment operator successfully deployed an integrated 360° around view monitoring and collision warning system for heavy equipment, significantly enhancing safety management across its entire fleet.

Key Customer Pain Points

● Significant Blind Spots from Complex Machinery

Heavy equipment such as excavators and loaders naturally have large blind zones due to structural limitations. During boom operation or turning, collision risks increase significantly.

● Frequent Human-Machine Interaction

Workers and machines often operate in close proximity. Without an effective heavy equipment collision warning mechanism, risks are difficult to detect in real time.

● Limited Perception in Harsh Environments

Night operations, dust, rain, and snow reduce visibility and impact traditional monitoring systems, requiring more robust perception technologies.

● Multi-Machine Coordination Challenges

Simultaneous operation of multiple machines leads to intersecting paths and dynamic working zones, affecting both safety and efficiency.

Solution

To address these challenges, the customer deployed STONKAM’s integrated 360° around view monitoring and radar-based collision warning system for heavy equipment, enabling real-time environmental awareness and proactive risk alerts.

AI 360 Around View Monitoring

The 360 around view monitoring provides full-surround visibility through advanced camera stitching and AI detection:

● 4-Channel 360° View: Four ultra-wide-angle HD cameras stitched into a seamless full-surround view
● 1-Minute Auto Calibration: Automatic software calibration with plane correction for fast deployment
● AI Full-Scene Detection: Integrated AI algorithms combining FCW (Forward Collision Warning) and BSD (Blind Spot Detection) for vehicles and pedestrians
● Multiple Protocol Support: Supports RTSP streaming, network touch protocol, and CAN touch protocol; real-time display on in-vehicle central control screen
● Rugged Design:
Monitor: IP66 waterproof
Control box & cameras: IP69K waterproof
Camera vibration resistance: ISO 16750-3 (5.9G)

77GHz Millimeter-Wave Radar

The heavy equipment collision warning capability is enhanced by radar sensing:

● Detection Range: 0.2–40 meters
● Detection Angle: Horizontal 120° / Vertical 14°
● All-Weather Operation: Unaffected by lighting, dust, or weather conditions
● Sensor Fusion: Works with vision system to enhance detection reliability

By tightly integrating AI 360° around view monitoring with millimeter-wave radar detection, the system performs multi-dimensional object evaluation and real-time risk level classification.

When a potential hazard is identified, the system automatically issues audible alarms and visual alerts, enabling operators to react quickly and prevent incidents before they occur.

Project Outcomes

● Reduced Safety Risks from Blind Spots

With real-time 360 around view monitoring and detection, operators gain clear visibility of surrounding personnel and obstacles, significantly reducing near-field collisions and accidental injuries caused by limited visibility.

● Improved Risk Response Speed and Accuracy

Through intelligent detection and graded alerts, operators can identify potential hazards faster, reducing reliance on manual judgment and improving on-site safety responsiveness.

● Reliable Performance in Complex Environments

The heavy equipment collision warning system maintains stable perception capabilities in night operations, dust, rain, and fog, ensuring continuous and safe equipment operation across diverse working conditions.

● Enhanced Multi-Machine Coordination Efficiency

By providing unified environmental perception and real-time feedback, different machines can better understand operational boundaries, reducing interference and repeated adjustments, thereby improving overall jobsite efficiency.

Customer Feedback

The customer commented:“We worked with STONKAM on this project. Honestly, they were very responsive and kept following up on our requirements until everything was clear and properly handled.”

FAQ

1. Is the solution suitable for different types of construction machinery?

Yes. It supports excavators, loaders, dump trucks, and other machinery. Customized installation solutions are available based on different vehicle structures and mounting conditions.

2. Can it be integrated with existing in-vehicle control systems?

Yes. The system supports RTSP streaming and is compatible with network touch and CAN touch protocols, enabling seamless integration with existing central control systems.

3. How reliable is the AI detection in real-world conditions?

By combining vision and radar sensing, the system improves detection stability and reduces false alarms through multi-source data fusion.

4. Is installation and deployment complicated?

No. The STONKAM AI 360° system supports 1-minute automatic calibration, significantly shortening installation and commissioning time, making it ideal for large-scale deployment.