Industrial Campus AI Surveillance

Multi-sensor perimeter security for small-medium factories, campuses, and gated communities. Scalable edge AI solutions combining cameras with radar integration at vehicle entrances.

PoC Scope: 50โ€“100 Cameras + Vehicle Entrance Radars

Use Case Profile

AI-powered surveillance for small-medium industrial facilities and gated communities. This guide covers deployments with 50โ€“100 cameras and radar sensors at truck/car entrances.

๐Ÿ“น Scale

50โ€“100 IP cameras with centralized or distributed edge processing

๐Ÿญ Environment

Factory floor, perimeter fence, loading docks, vehicle entry/exit gates

๐Ÿง  Analytics

Intrusion detection, LPR, PPE compliance, vehicle tracking, behavior analysis

๐Ÿ“ก Radar

2โ€“4 units at truck/car entrances for vehicle detection and speed monitoring

Infrastructure Planning

Calculate power and network switch requirements before hardware selection.

โšก Power Calculation

Total PoE Power = Cameras ร— Avg Power per Camera + Edge Nodes ร— Node Power + Switches ร— Switch Power + Radar ร— Radar Power + 20% Headroom
ComponentTypical Powerร—50 Cams
PoE Camera (4K)12โ€“25W each600โ€“1,250W
PoE Camera (1080p)8โ€“15W each400โ€“750W
Edge Node (RK3588+Hailo)25W each50W (ร—2)
Edge Node (QCS8550)40W each40W (ร—1)
PoE Switch (24-port)30W + PoE budget60W (ร—2)
Radar Sensor10โ€“20W each40W (ร—2)
Example (50 cams @ 1080p):
Cameras: 50 ร— 12W = 600W
Edge nodes: 2 ร— 25W = 50W
Switches: 2 ร— 30W = 60W
Radars: 2 ร— 15W = 30W
Subtotal: 740W + 20% = ~900W total

๐Ÿ”Œ Network Switch Planning

PoE Budget per Switch = Cameras ร— Max Camera Power Switches Needed = Total Cameras รท Ports per Switch Uplink = 10GbE to core (recommended)
CamerasSwitch ConfigPoE Budget
251ร— 24-port PoE+370W
502ร— 24-port PoE+740W
753ร— 24-port PoE+ or 2ร— 48-port1,110W
1002ร— 48-port PoE++ or 4ร— 24-port1,480W
Recommended Switches:
Entry: TP-Link TL-SG1024PE (24-port, 250W)
Mid: Ubiquiti USW-Pro-24-PoE (400W)
Premium: Cisco CBS350-24FP (370W)

๐Ÿ’ก Storage Calculation

Formula: Cameras ร— Bitrate (Mbps) ร— 3600 ร— 24 ร— Days รท 8 รท 1,000,000 = TB
Example (50 cams, 4 Mbps, 30 days): 50 ร— 4 ร— 3600 ร— 24 ร— 30 รท 8 รท 1,000,000 = ~65 TB
With smart recording (motion only), reduce by 50โ€“70% โ†’ ~20โ€“30 TB

Hardware Recommendations

Three tiers optimized for different deployment requirements and budget constraints. All platforms support ONVIF cameras and standard VMS integration.

RK3588 + Hailo-8

ENTRY TIER
  • AI Performance32 TOPS (6+26)
  • Camera Channels24โ€“32 @ 1080p
  • Power Draw15โ€“25W
  • CPU8-core ARM A76/A55
  • Video Decode8K60 / 32ร— 1080p
  • NetworkDual GbE

Qualcomm QCS8550

MID TIER
  • AI Performance48 TOPS
  • Camera Channels48โ€“64 @ 1080p
  • Power Draw25โ€“40W
  • CPU8-core Kryo
  • Video Decode8K30 / 64ร— 1080p
  • Network2.5GbE / 10GbE opt

NVIDIA Jetson Orin NX

PREMIUM TIER
  • AI Performance100 TOPS
  • Camera Channels16โ€“32 @ 4K
  • Power Draw25โ€“60W
  • GPU1024 CUDA cores
  • SpecialRadar/LiDAR fusion
  • NetworkGbE + 10GbE opt

Detailed Reference Design

Complete architecture for a mid-range deployment: 50 cameras + 2 radars at vehicle entrances.

๐Ÿ“ Mid-Range Design: 50 Cameras + 2 Radars

Typical small factory or gated community with single entry/exit point

System Architecture

๐Ÿ–ฅ๏ธ
VMS Command Center
Network Optix Nx Witness / Frigate NVR
Intel N100/N200 Mini PC โ€ข 4TB NVMe โ€ข Central Monitoring
๐Ÿ’พ
NAS Storage
4-Bay NAS Array
32TB Raw โ€ข RAID5 โ€ข 30-Day Retention
10GbE Uplink
๐Ÿ”€
Core Switch (L3)
24-Port + 4ร— SFP+
VLAN: Cams | Edge | Mgmt | Radar
๐Ÿ”Œ
PoE Switch 1
24-Port 370W
Cams 1โ€“24
๐Ÿ”Œ
PoE Switch 2
24-Port 370W
Cams 25โ€“50
๐Ÿง 
Edge Node 1
RK3588+Hailo
25W โ€ข Cams 1โ€“25 + Radar 1
๐Ÿง 
Edge Node 2
RK3588+Hailo
25W โ€ข Cams 26โ€“50 + Radar 2
๐Ÿ“น
Zone A
16 Cameras
Factory Floor
๐Ÿ“น
Zone B
8 Cameras
Perimeter
๐Ÿ“ก
Radar 1
Entry Gate
77GHz
๐Ÿ“น
Zone C
16 Cameras
Perimeter
๐Ÿš—
Gate
10 LPR Cams
4K + WDR
๐Ÿ“ก
Radar 2
Exit Gate
77GHz

Zone Analytics

Zone A: PPE detection, forklift safety, worker counting
Zone B+C: Intrusion detection, loitering, fence monitoring
Gate: LPR, vehicle tracking, access logging
Radar: Vehicle detection, speed, queue length

Component Specifications

Component Specification Qty Power Network
IP Cameras (1080p) 4MP turret/bullet, PoE, IR 30m, ONVIF 40 12W each = 480W 100Mbps each
IP Cameras (4K LPR) 8MP bullet, motorized zoom, WDR 10 18W each = 180W 100Mbps each
Edge Node RK3588 + Hailo-8 M.2 (32 TOPS) 2 25W each = 50W 2ร— GbE each
PoE Switch 24-port PoE+ (370W budget), 2ร— SFP+ 2 30W each = 60W 10GbE uplink
Core Switch L3 managed, 24-port GbE + 4ร— SFP+ 1 35W 10GbE backbone
VMS Server Intel N200 Mini PC, 32GB RAM, 4TB NVMe 1 25W 2.5GbE
NAS Storage 4-bay NAS, 4ร— 8TB HDD (32TB raw) 1 50W 2ร— GbE
Radar Sensor 77GHz digital imaging, 150m range 2 15W each = 30W Ethernet / CAN
UPS 1500VA / 900W, 30min runtime 1 โ€” โ€”

Power Budget Summary

ComponentPower (W)
40ร— 1080p Cameras (PoE)480W
10ร— 4K LPR Cameras (PoE)180W
2ร— Edge Nodes50W
2ร— PoE Switches (base)60W
1ร— Core Switch35W
1ร— VMS Server25W
1ร— NAS Storage50W
2ร— Radar Sensors30W
Subtotal910W
+ 20% Headroom182W
TOTAL POWER~1,100W
UPS Recommendation: 1500VA / 900W minimum for 30-min runtime on core equipment (switches + edge nodes + VMS)

Network Requirements

SegmentBandwidthNotes
Camera โ†’ PoE Switch50ร— 4Mbps = 200 MbpsPer switch: 100 Mbps
PoE Switch โ†’ Edge Node2ร— 100 MbpsProcessed video streams
Edge Node โ†’ VMS2ร— 50 MbpsMetadata + alerts + selective video
VMS โ†’ NAS200 Mbps sustainedRecording streams
Core Uplinks10GbE recommendedFuture-proof, burst capacity
VLAN Configuration:
VLAN 10: Camera network (isolated)
VLAN 20: Edge nodes + VMS
VLAN 30: Management (switches, IPMI)
VLAN 40: Radar sensors

Bill of Materials (Estimated)

ItemQtyUnit PriceTotal
4MP PoE Turret Camera40$80$3,200
8MP LPR Bullet Camera10$200$2,000
RK3588 + Hailo-8 Edge Box2$1,000$2,000
24-Port PoE+ Switch (370W)2$350$700
L3 Core Switch (24-port)1$500$500
Intel N200 Mini PC (VMS)1$400$400
4-Bay NAS + 32TB HDD1$1,200$1,200
77GHz Digital Imaging Radar2$600$1,200
1500VA UPS1$300$300
Cabling + Accessories1$500$500
ESTIMATED HARDWARE TOTAL $12,000 โ€“ $15,000

โœ… Why This Architecture Works

Distributed Processing: Edge nodes handle AI inference locally, reducing central server load by 90%+.
Redundancy: Each edge node covers half the cameras; if one fails, the other continues.
Scalability: Add more edge nodes or upgrade to QCS8550 for 100+ cameras.
Radar Integration: Edge nodes receive radar data via Ethernet, fuse with camera feeds for vehicle tracking.

Radar Integration

Complement camera coverage with radar sensors at vehicle entrances for all-weather detection and velocity measurement. Essential for truck/car gate monitoring.

๐Ÿ“ก Digital Imaging Radar (Premium)

Type: 4D Digital Imaging Radar

Range: 150โ€“350m

Resolution: <1ยฐ angular

Interface: Ethernet / CAN

Use Case: Large vehicle tracking, classification

Power: 15โ€“25W

Price Range: $1,500โ€“2,500

๐Ÿ“ก Smartmicro (SMS) โ€“ Mid-Range

Type: 77GHz FMCW Radar

Range: 100โ€“200m

Resolution: 1.5ยฐ angular

Interface: CAN / RS-485 / Ethernet

Use Case: Traffic monitoring, industrial

Power: 10โ€“15W

Price Range: $800โ€“1,500

๐Ÿ“ก India/Taiwan OEM โ€“ Entry

Examples: Steradian, waveant, local OEMs

Type: 77/79GHz mmWave

Range: 50โ€“150m

Interface: UART / SPI / CAN

Use Case: Basic vehicle detection

Power: 5โ€“10W

Price Range: $300โ€“800

โš ๏ธ Radar + Camera Fusion

For true sensor fusion (combined tracking), use Jetson Orin with ROS2 or NVIDIA Isaac ROS. Entry/mid-tier platforms (RK3588, QCS8550) work best with radar as a separate alert trigger rather than fused tracking โ€” the edge node receives radar events via MQTT/Ethernet and correlates with camera zones.

Software Stack

Recommended software components for edge analytics, VMS, and alerting.

VMS Nx Witness, Milestone, Frigate (OSS)
Edge Analytics DeepStream, Hailo Tappas, RKNN
LPR Engine OpenALPR, Plate Recognizer
Alerting MQTT, Telegram, PagerDuty
Storage MinIO, TrueNAS, Synology
Radar Integration MQTT broker, custom scripts

Platform Compatibility

Software RK3588 QCS8550 Jetson Orin Notes
NVIDIA DeepStream โŒ โŒ โœ… Jetson only
Hailo Tappas โœ… โŒ โœ… Requires Hailo M.2
RKNN-Toolkit2 โœ… โŒ โŒ Rockchip only
Frigate NVR โœ… โœ… โœ… All platforms
Nx Witness โœ… โœ… โœ… ARM supported

Deployment Sizing Guide

Hardware requirements for small-medium industrial facilities and gated communities.

Deployment Cameras Radars Edge Nodes PoE Switches Power (Total) Storage (30d) Est. Budget
Small Gate Community 25โ€“30 1 1ร— RK3588+Hailo 1ร— 24-port ~500W 15โ€“20 TB $5,000โ€“7,000
Medium Factory 50 2 2ร— RK3588+Hailo 2ร— 24-port ~1,100W 30โ€“40 TB $12,000โ€“15,000
Large Campus 75โ€“100 2โ€“4 2ร— QCS8550 or 3ร— RK3588 2ร— 48-port or 4ร— 24-port ~1,800W 50โ€“80 TB $20,000โ€“30,000

โœ… Quick Storage Formula

Standard Recording: Cameras ร— 4 Mbps ร— 0.04 ร— Days = TB
Smart Recording (motion): Reduce by 50โ€“70%
Example: 50 cams ร— 4 Mbps ร— 0.04 ร— 30 days = ~24 TB (smart: ~8โ€“12 TB)

Alert & Notification Architecture

Edge nodes process AI inference locally and trigger real-time alerts directly โ€” no cloud dependency for critical notifications.

๐Ÿง 
Edge Node AI Pipeline
Camera Feed โ†’ Inference โ†’ Event Detection
Person | Vehicle | PPE | Intrusion | LPR
Alert Decision Engine (Rules + Threshold + Dedup)
๐Ÿ“ก
MQTT
Mosquitto
<100ms
๐Ÿ”—
Webhook
REST API
<500ms
โœˆ๏ธ
Telegram
Bot API
<1s
๐Ÿ’ฌ
WhatsApp
Business
<2s
๐Ÿ“ง
Email
SMTP
1-5s
๐Ÿ””
Siren
GPIO/Relay
<50ms
๐Ÿ“Š
Node-RED
Dashboard
๐Ÿ 
Home Assist
Automation
๐Ÿ–ฅ๏ธ
VMS
Nx / Frigate
๐Ÿ‘ฎ
Security
Mobile App
๐Ÿ‘”
Management
Escalation

Alert Methods Comparison

Method Latency Complexity Snapshot Best For
MQTT <100ms Low Via URL IoT dashboards, Node-RED, Home Assistant
Webhook/REST <500ms Low Base64/URL VMS integration, custom backends
Telegram Bot <1s Low โœ… Inline Security guards, mobile alerts
WhatsApp Business <2s Medium โœ… Inline Management alerts
Email (SMTP) 1-5s Low โœ… Attachment Logs, non-urgent alerts
Siren/Relay (GPIO) <50ms Low N/A Physical alarms, strobe lights

Recommended Stack for PoC

MQTT Broker Mosquitto (on edge or VMS)
Primary Alert Telegram Bot (free, instant)
Dashboard Node-RED + Grafana
Escalation WhatsApp / Email

๐Ÿ’ก PoC Alert Flow

Edge Node detects event โ†’ publishes to MQTT โ†’ Telegram Bot sends photo + alert to security group โ†’ if no acknowledgment in 2 min โ†’ escalate to WhatsApp/Email (management)

Ready to Deploy?

VikaBot provides end-to-end industrial surveillance solutions โ€” from hardware sourcing to system integration and ongoing support.

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