InterCycle

InterCycle is a solution based on factory digital twin created from CCTV data: For this event built and tested using only public CCTV clips of an Industrial plant in Turkey (Önal & Dandıl 2024, CC BY 4.0). We build an observer layer that works with pre-existing CCTV cameras to detect and track people and forklifts with RF-DETR and ByteTrack, fit the motion dynamics, and compile each zone into Isaac Sim and Nav2 worlds. The proposed twin models each press's stroke cycle and its running, stopped, tripped, resetting and held states, replays real people and forklift movements at real speed within synthetic days, and learns layered collision volumes (L0–L3) in which unknown or not-yet-learned space counts as occupied. A simulated ANYmal-D robot enters a machine zone only when the twin's observer forecast says, with high confidence, that the machine stays stopped over the whole planning horizon and the robot's own camera sees no motion. InterCycle is an advisory layer, not a safety function: light curtains and a simulated stand-in for the robot's safety scanner remain the safety layer, and the Observer running Gemma 4 31B-IT on AMD Token Factory is the higher layer that allows the robot to work inside the environment.