By combining AI-driven human form and object detection with robust hardware and intuitive interfaces, Leica Xsight360 delivers real-time awareness and insights that adapt to the dynamic nature of construction environments.
Staying safe in heavy construction environments is paramount, no matter the site conditions. Artificial intelligence (AI) plays a key part in this. As it continues to transform industries, its application in heavy construction is helping to build a safety-first culture that prioritises people.
One such application is the Leica Xsight360 safety awareness solution, due to be released in Australia early next year. It represents a leap forward in how operators and site personnel are protected. Powered by Presien, the system is manufactured by Leica Geosystems, part of Hexagon.
However, as with any emerging technology, it’s crucial for safety professionals to understand not just what the system does, but how it does it.
Hexagon’s Machine Control Division Product Manager Brad Mullis takes a deep dive into the main components of the Leica Xsight360 solution. He explains how, by combining AI-driven human form and object detection with robust hardware and intuitive interfaces, the product delivers real-time awareness and insights that adapt to the dynamic nature of construction environments.
“The Leica Xsight360 solution leverages industry-leading edge-AI models to deliver real-time object detection and operator alerting,” Brad said. “In addition, occupational health and safety managers benefit from its AI-powered incident auditing and reporting capabilities, which support the development of proactive and data-driven safety strategies.”
The system comprises a set of hardware components that can be installed on any vehicle. These include the Leica CRS360 AI processing unit, the Leica CRS214 in-cabin display, the Leica CRS240 Automotive Ethernet camera and the Leica CR50 connectivity module.
Every detection is geolocated to identify danger zones and high-risk areas on site, enabling the implementation of appropriate measures to prevent future incidents.
Visual alert architecture and operator experience
Brad said that the Leica Xsight360 system indicates all visual alerts through an interface via the Leica CRS214 CAN-based operator display.
“Leica Xsight360 visual alerts are fully configurable to suit different site requirements and operator needs. This includes customising alert colour, flashing pattern and buzzer settings separately for general and critical detections,” he said.
“Configurations are managed through the Leica Xsight360 setup app on the online customer platform by an authorised user. Operators cannot change alert settings directly from the in-cab display. Access may be granted to operators or limited to designated personnel such as safety officers or site engineers.”
The Leica Xsight360 system supports flexible camera configurations tailored to different machine types. Using up to six 120° wide-angle cameras, the system can deliver 360° awareness. Machines may be configured with partial coverage, depending on the operational risk zones and application.
Brad said the Leica CRS214 in-cabin display presented a sector-based alert layout that corresponds to the actual camera coverage installed on the machine.
“The display provides real-time illuminated segments that indicate both the direction and severity of detections, aligned precisely with the configured fields of view. This ensures the operator is only alerted to activity in zones that are actively monitored,” he said.
“For enhanced situational awareness, the system can be integrated with the Leica MC1 machine control solution, enabling operators to view live camera feeds on their Leica Geosystems machine control display.
“These feeds are not stitched into a composite view but can be cycled or displayed in parallel. Upon detection, the Leica MC1 interface can be configured to automatically switch to the relevant camera stream, providing immediate visual context.”
Camera mounting stability options
Leica Xsight360 supports a wide range of camera mounting options designed for ease of use and flexibility on all machine types, including:
- Magnetic/adhesive mounts — high-strength magnetic bases with adhesive backing, suitable for metal, plastic or glass surfaces, originally developed and tested in vibration-prone machine control sensors
- Rail mounts — clamping brackets compatible with rail diameters from 17 to 50mm, offering 360° camera rotation
- Flat base plates — bolt-on or weldable plates with multi-orientation hole patterns.
“Camera brackets support vertical, horizontal, side and inverted orientations with adjustable tilt angles,” Brad said.
“A dual screw locking mechanism ensures stability under vibration. All cameras use automotive Ethernet cables with M12 connectors, and optional extension cables allow for placement of disconnect points in safe and accessible areas.”
Brad said that Leica Xsight360 on-machine components have been engineered for machines that undergo frequent assembly and disassembly cycles.
“The camera’s quick-connect/disconnect rear plugs enable easy removal and reinstallation without tools,” he said.
“Brackets are designed to maintain alignment under vibration and resist degradation from repeated handling. Cable systems support colour-coded labelling (from a local installer) to simplify reinstallation, while the stress-relief loops and dust caps protect connectors during frequent connection/disconnection routines.”
Installation, calibration and configuration
Leica Xsight360 eliminates the need for traditional calibration tools such as checkerboards. Cameras are pre-calibrated at the factory, and IP addresses are automatically assigned upon connection.
System calibration is performed during setup using a wizard-driven interface on a standard laptop or tablet over the system’s internal Wi-Fi or over-the-air through the online platform. It is designed to be simple, with no advanced technical skills required.
The calibration process includes:
- Camera alignment
- Zone definition using physical markers (e.g. cones)
- Detection validation.
“The AI engine does not require calibration. Users simply select the operating environment from predefined options, and the system adjusts detection parameters accordingly,” Brad said.
“If a camera is moved or replaced, the system compares the current view to a stored reference image and prompts recalibration if needed.
“Following the configuration, a walk-around test is conducted to verify detection zones and system functionality. Detection zones can be adjusted via the Manual Sensor Configuration, as required.
“The installer will need to verify that the Alert Trigger is behaving as expected. It is important to note that the system will be inactive in safe mode (e.g. hydraulic lock engaged) and activate only in working mode.
“Detection events are uploaded to the cloud, and a calibration certificate is generated and can be stored in the vehicle.”
Fail-safe mechanisms and fault handling
Leica Xsight360 includes multiple fail-safe mechanisms to ensure operational integrity:
Camera disconnection or damage triggers a camera failure icon on the in-cab display and disables the affected sector, while the rest of the system remains active.
Obscured or dirty lenses are flagged with a ‘camera obscured’ icon, flagging that detection in the sector is unavailable.
Low-light conditions prompt a low-light warning for the affected zone.
Startup diagnostics verify firmware versions, image quality, frame rate and detection capability.
Software failure results in an error icon and halts detections until resolved.
Alert trigger signal failure defaults the system to active detection mode to prevent unsafe silence.
All faults are logged locally and to the cloud. The Device Maintenance dashboard provides real-time visibility into system health, and alerts can be escalated via email or SMS.
“Operators cannot disable the system without physically tampering with the wiring,” Brad said.
“Any wiring modifications are time-stamped and logged in the cloud. If the system is unplugged or the fuse is removed, the machine will be flagged as inactive during expected operating hours.
“Alert deactivation muting can only be performed remotely by authorised personnel via the cloud interface. The system’s input trigger ensures alerts are only active when the machine is in a hazardous state.”
C.R. Kennedy
The Xsight360 safety awareness solution will be available in Australia through spatial technology specialist and distributor C.R. Kennedy (CRK).
CRK National Manager for Machine Control Nick Leith said the system’s visual AI models are trained for heavy construction operations and continuously improve performance through machine learning.
“The Leica CRS360 AI processor runs Presien’s most advanced model to date — refined over 700,000 hours of real-world operation on construction sites — delivering low-latency operator alerts with minimal false alarms,” he said.
“Utilising proven AI detection technology, purpose-built for construction environments, Leica Xsight360 mitigates risks in real time by detecting hazards to keep people safe on site. The system supports up to six cameras, providing coverage on any construction vehicle to detect people, other vehicles and construction cones to reduce the likelihood of accidents.
“We want to get innovations such as these to key players in the market to test for spatial awareness and safety reporting.
“It will be a fantastic application for toolbox meetings and just general reporting for overall operations as well.”
More information: www.crkennedy.com.au/