AI Camera vs Traditional Safety Sensors: Which Is More Effective?
Technical comparison of AI cameras vs light curtains, laser scanners, and UWB systems. A guide to choosing the right safety solution.
From Traditional Sensors to AI Cameras: A Paradigm Shift in Industrial Safety
Technology selection in industrial safety is a critical decision that directly impacts workers' lives. For decades, light curtains, laser scanners, and more recently UWB (Ultra-Wideband) systems have been fundamental components of industrial safety. But AI camera systems now offer a new approach that transcends the limitations of these technologies.
In this article, we objectively compare the strengths and weaknesses of each technology.
Light Curtain
How it works: Creates an infrared beam array between a transmitter and receiver. Any object breaking the beam is detected and the machine is stopped.
Strengths:
- Proven technology with decades of field experience
- High SIL/PL levels (Type 4 = SIL3/PLe)
- Fast response time
Weaknesses:
- Single-line protection — cannot cover wide areas
- Cannot distinguish between material and human — muting required
- Muting bypass creates serious safety gaps
- Separate installation needed for each machine
Safety Laser Scanner
How it works: Scans surrounding objects with a rotating laser beam and generates a signal when entry into a defined safety zone occurs.
Strengths:
- Wide scanning angle (180°-270°)
- Flexible zone definition
- Common use in AGVs and robot cells
Weaknesses:
- Operates in single plane — no 3D detection
- No object classification (cannot distinguish human from material)
- Performance may degrade in dusty or smoky environments
- Typically IP65/IP67 — IP69K is rare
UWB (Ultra-Wideband) Systems
How it works: Calculates position using radio signals between UWB tags on workers/vehicles and anchors installed throughout the facility.
Strengths:
- Centimeter-level positioning accuracy
- 3D position tracking
Weaknesses:
- Tags required on every worker — problematic for visitors and subcontractors
- Tag battery maintenance and replacement needed
- Facility-wide anchor infrastructure required (every 15-30m)
- Signal reflection from metal surfaces — incorrect positioning
- Untagged personnel remain unprotected
- Position-only — no PPE detection or behavior analysis
AI Camera System
How it works: Uses deep learning models to detect, identify, and classify humans, vehicles, and objects in real time through camera imagery.
Strengths:
- Tagless operation — no wearable devices needed
- Object classification — human, forklift, material differentiation
- Wide area coverage — single camera covers large zones
- Multi-function — PPE, collision avoidance, zone monitoring, press safety on one platform
- Hand-material differentiation — eliminates muting in press applications
- Edge AI — no cloud needed, data privacy preserved
Considerations:
- Camera field of view and mounting point must be properly planned
- Additional lighting may be needed in extremely dark environments
Comparison Table
| Criterion | Light Curtain | Laser Scanner | UWB | AI Camera |
|---|---|---|---|---|
| Wearable device needed | No | No | Yes (tag) | No |
| Object classification | No | No | No | Yes |
| Wide area coverage | No | Partial | Yes | Yes |
| Multi-function | No | No | No | Yes (22+) |
| Maintenance burden | Low | Low | High (battery, anchor) | Low |
| Dusty environment durability | Medium | Low | High | High (IP69K) |
| Infrastructure cost | Per machine | Per machine | Facility-wide | Per camera |
Which Technology Should I Choose?
Technology selection depends on the application scenario:
- Single machine protection (press): Light curtain is a proven solution. But if you're experiencing muting issues, AI camera is a viable alternative.
- Robot cell: Laser scanner + AI camera combination provides the most comprehensive protection.
- Forklift-pedestrian safety: If tag compliance is difficult, AI camera is the most suitable solution.
- Facility-wide multi-risk: AI camera covers multiple risks on a single platform, reducing total cost.
ISEE-CAM integrates seamlessly with your existing safety infrastructure via OPC-UA and Modbus TCP protocols, including Pilz, Siemens, and Allen-Bradley safety PLCs. It can also be used as a complementary layer alongside your existing sensors.
To determine the right solution, take advantage of ISEE Vision's free site survey.