Komatsus AI Safety System Cuts Construction Site Collisions

Modern construction sites represent a delicate balance between efficiency and safety, where workers and heavy machinery must operate in close proximity. While fatalities from hydraulic excavators and other construction equipment have decreased in recent years, the risk remains ever-present. Each accident serves as a sobering reminder of the need for enhanced protective measures.

Komatsu, a leader in construction machinery, has long prioritized worksite safety. The company's KomVision system, now standard on PC120 to PC1250-11 series equipment, uses multiple cameras to provide operators with a comprehensive overhead view of their surroundings. Building on this foundation, Komatsu developed the KomVision Person Detection and Collision Mitigation System - an advanced solution that actively prevents accidents through real-time monitoring and automated responses.

The evolution from KomVision to its enhanced version represents a paradigm shift in construction safety. While the original system helped operators identify potential hazards, the upgraded version automatically detects personnel near machinery and initiates protective measures. When the system identifies workers in danger zones, it immediately alerts the operator through visual and auditory warnings while simultaneously stopping equipment movement to prevent collisions.

Komatsu's engineering team implemented innovative strategies to accelerate development while maintaining affordability:

• Software-First Approach: Leveraged existing KomVision hardware, implementing new capabilities through software updates rather than hardware modifications
• Optimized Camera Utilization: Enhanced image processing algorithms to maximize the potential of current camera systems, avoiding additional sensors

This methodology allowed Komatsu to deliver advanced safety features to existing equipment through simple software upgrades, dramatically increasing the system's accessibility and value.

The system's core lies in its sophisticated person-detection algorithm, developed using deep learning technology. Engineers created detailed human models by analyzing thousands of images featuring construction workers in various poses and scenarios. Special attention was given to common worksite attire - including hard hats, safety vests, and work uniforms - to ensure reliable detection in real-world conditions.

Unlike automotive applications, construction equipment presents unique challenges due to differing camera angles and heights. Komatsu addressed this by collecting extensive worksite imagery specifically tailored to hydraulic excavators, then training the system accordingly. The algorithm assigns confidence scores to potential detections, only triggering alerts when the probability of human presence exceeds carefully calibrated thresholds.

Recognizing the importance of bringing enhanced safety to already-deployed machinery, Komatsu introduced remote ECU updates in November 2020. Using the company's existing remote programming infrastructure - originally designed for quality improvements - authorized users can now upgrade their systems by purchasing unique product key cards. This secure process prevents unauthorized modifications while making advanced safety features available to a wide range of equipment owners.

Following successful implementation on PC200-11 models, Komatsu has progressively expanded the system's availability to PC20t, PC10t, and HB20t series machines. Each new equipment category undergoes rigorous testing to account for variations in camera placement and perspective. The company continues to refine the technology while working toward comprehensive coverage across its product lineup.

Komatsu's Person Detection and Collision Mitigation System exemplifies the company's dedication to worksite safety through technological innovation. By transforming passive monitoring into active protection, the system represents a significant advancement in construction equipment safety. As Komatsu continues to develop and refine these solutions, the construction industry moves closer to eliminating preventable accidents between workers and machinery.