Human Form Recognition –
MachineSense Vision Kit
Amber Zone (Warning): 5m • Red Zone (Exclusion): 2m
Document title | Plinx Zone Configuration Guide – Human Form Recognition System |
Applies to | Plant machinery fitted with the Plinx M3/M4 human form recognition system |
Zones defined | Amber zone (Warning) – rectangular, 5m from the machine |
Prepared by | Ollie Dunn - Operations |
Organisation | Plinx |
Date issued | 12 August 2026 |
Version | 1.0 – Draft for review |
Approved by | (sign / print name) |
Next review date |
|
1. Purpose and Scope:
This guide describes the standard step-by-step procedure for configuring the detection zones used by the Plinx human form recognition system fitted to plant machinery. The system uses four cameras – mounted in the Front, Back, Left, and Right facing positions – each is able to be fixed at a set angle based on its orientation.
Two configurable detection zones are configured for each camera, offset out from the machine's own footprint by a fixed distance on every side. Because the machine is longer front-to-back than it is wide, the resulting zone rectangles have shorter edges at the Front and Rear and longer edges down the Left and Right sides:
• Amber zone (Warning) – a configurable zone set 5 metres out from the machine in 4 directions
• Red zone (Exclusion) – a configurable zone set 2 metres out from the machine in 4 directions
This procedure applies whenever a machine's cameras are being newly configured, re-configured after a camera or mounting change, or checked as part of a scheduled verification.
2. Safety Precautions:
Read before starting: • Do not carry out this procedure alone – work with a second competent person where the machine cannot be fully isolated during configuration. • Confirm the machine's isolation / lock-out status with your site's isolation procedure before entering the 2m red zone to place markers. Treat the machine as live unless you have personally confirmed isolation. • Wear all PPE required for the area in which the machine is sited. • Do not bypass, disable, or override any Plinx camera, interlock, or safety function to complete this procedure – configuration must be carried out with the system's safety functions active wherever possible. • If a camera or zone cannot be configured to give full 360° coverage with no blind spots or gaps along any straight edge, stop and report this to your supervisor before returning the machine to operation. • This guide is a general procedure template for the Plinx system. Always follow Plinx' own installation and configuration instructions and your site's risk assessment and safe system of work alongside this guide. |
3. Equipment Required:
• Floor markers / cones – minimum 8 for the 2m zone and 8 for the 5m zone (4 corners plus a mid-point marker on each of the two longer Left/Right sides per ring); more markers may be used for a smoother, straighter traced outline
• Tape measure or laser distance meter (measures accurately to 2m and 5m from the machine's outer edge / danger points, at 90° to each side of the machine)
• Laptop or configuration terminal with access to the Plinx camera / vision system software, and valid login credentials
• Site PPE as required for the area (hi-vis, hard hat, safety footwear)
• This guide and a copy of the machine's Plinx zone configuration record sheet
4. Zone Layout Reference:
The diagram below shows the intended layout: the four Plinx cameras positioned around the machine, the rectangular 2m red exclusion zone, and the rectangular 5m amber warning zone. Floor markers are placed at each of the four corners of both rectangles – each corner sits within the overlapping field of view of the two adjacent cameras that meet there, giving full 360° coverage with no blind spots. An additional mid-point marker is placed on each of the longer Left and Right sides, at both 2m and 5m, so the boundary can be traced as a straight, gap-free line along its full length.
5. Step-by-Step Procedure:
Carry out Steps 2 to 6 individually for each of the four cameras (Front, Back, Left, Right) before moving on to Step 7.
STEP 1 Plot the Zone Perimeters
Using the floor markers and a tape measure or laser distance meter, mark out the two rectangular zone perimeters on the ground all the way around the machine. Measure out from the machine at 90° to each side – not on the diagonal – so each rectangle's edges stay parallel to the machine's own sides:
1. Measure and place a floor marker at each of the four corners of the 2m rectangle (red exclusion zone).
2. Measure and place a floor marker at each of the four corners of the 5m rectangle (amber warning zone).
3. The Left and Right sides of each rectangle are longer than the Front and Rear sides. Place an additional floor marker at the mid-point of each long Left and Right side, at both 2m and 5m, so there is a straight reference line along the full length of that side with no gap.
4. Check that every corner marker is visible in at least two of the four cameras – the two cameras whose views meet at that corner – so the full perimeter has overlapping coverage with no gaps.
5. Do not proceed until the complete marker layout at both 2m and 5m – all four corners plus both mid-side markers on each ring – is in place and confirmed.
STEP 2 Log Into the Camera
Connect to the Plinx camera / vision system configuration software and log in using your credentials.
6. Select the specific camera to be configured (Front, Back, Left, or Right).
7. Confirm the correct camera and machine are selected before making any changes.
STEP 3 Trace the Red Zone (2m Exclusion Zone)
Using the pre-configured plotted way-points in the Plinx configuration software, trace the red exclusion zone as a rectangle matching the 2m floor markers as seen in that camera's live view.
8. Plot each corner of the zone shape onto the corresponding 2m corner marker visible on screen.
9. Where the Left or Right side of the rectangle runs through this camera's view, plot the line through the mid-side marker as well as the corners, so the edge is drawn straight with no gap or bulge.
10. Check the traced shape follows the ground accurately along every side, with no gaps between the shape and the markers.
STEP 4 Trace the Amber Zone (5m Warning Zone)
Repeat the same process for the amber warning zone, tracing it as a rectangle matching the 5m floor markers as seen in that camera's live view.
11. Plot each corner of the zone shape onto the corresponding 5m corner marker visible on screen.
12. Where the Left or Right side of the rectangle runs through this camera's view, plot the line through the mid-side marker as well as the corners, so the edge is drawn straight with no gap or bulge.
13. Confirm the amber zone rectangle fully encloses the red zone rectangle on all sides with no overlap errors.
STEP 5 Save the Zone Shapes
Save the configured red and amber zone shapes to the camera.
14. Confirm the save/apply action has completed and the configuration has been written to the camera.
15. Repeat Steps 2–5 for each remaining camera (Front, Back, Left, Right) until all four are configured.
STEP 6 Visually Check Each Camera
Once all four cameras are configured, visually check each one in turn to confirm the zones are correct.
16. View the live camera feed with the zone overlay displayed.
17. Confirm the red and amber zone boundaries align with the floor markers along every straight edge, with no gaps, overlaps, or misalignment – paying particular attention to the longer Left and Right sides.
18. Confirm there are no blind spots between adjacent camera views around the full 360°, and that each corner is picked up cleanly by both of the cameras that should see it.
19. If any zone does not match the floor markers, or a gap appears along a long side, repeat Steps 3–5 for that camera before continuing.
STEP 7 Disconnect from the Cameras
Once all four cameras have been checked and confirmed correct, log out of / disconnect from the Plinx camera configuration software and close the session securely.
STEP 8 Collect the Floor Markers
Remove all floor markers from the 2m and 5m perimeters (all corners and mid-side markers) and return them to storage. Confirm the area around the machine is clear and returned to its normal operating condition.
STEP 9 Walk-Around Verification
With the floor markers removed, carry out a walk-around test of the machine to confirm the Plinx system is working correctly in normal operation:
20. Walk around the machine through all four camera views (Front, Back, Left, Right), including along the full length of the longer Left and Right sides.
21. Confirm the Plinx visual Driver Display picks up and displays the human form correctly in each of the four views. Detection should display as a flashing LED, either Red or Amber.
22. Confirm that amber (warning) and red (exclusion) alerts trigger correctly as you cross each zone boundary, with no gaps in detection along any side.
23. Record the result of this check for each camera in the sign-off table below.
6. Verification and Sign-Off
Complete this table once the full procedure has been carried out and the walk-around verification (Step 9) is complete for all four cameras.
Machine / Asset ID | Camera checked | Result (Pass/Fail) | Checked by / Date |
| Front |
|
|
| Back |
|
|
| Left |
|
|
| Right |
|
|
Configuration completed by: Date:
Reviewed / verified by: Date: