BayOne

How it fits together

BayOne, part by part

Scroll or tap a part. Press “See the 3D CAD design” to watch the model, built from our CAD, light each part up and show how it connects.

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1. 01

   The whole BayOne

   The tipping bay's own traffic light runs the bay: a bay camera and a heat camera in the head's bay-side wall look down over the push wall at every load and the pile, a radar beside them finds people near the reversing truck and the loader, an approach camera behind the door reads the truck's fleet number, and the brain on the head floor turns that into bay, person, banned-item, load, hot-spot, pile and smoke calls on the light's own red, amber and green aspects and one app, over LTE-M.

2. 02Brain

   Raspberry Pi 5 (on the signal head floor)

   The brain: it runs the bayone-fw program

3. 

   03

   Bay and approach cameras

   The bay camera in the bay-side wall, 22 degrees down over the push wall top, sees every tipped load, banned items, the pile and its 4 m line; the approach camera behind the door reads the fleet number of the truck reversing in

   Raspberry Pi 5 (on the signal head floor) · CSI-2 ribbons (both on the Pi 5's two camera ports, inside the head) · Frames at 10 fps while a truck tips; a bay frame every 10 s overnight; 10 s clips around calls

4. 04

   Heat camera

   Beside the bay camera, 12 degrees down along the bay: surface temperature of the whole pile and of each fresh load, so a hot spot that keeps growing or a hot battery is found

   Raspberry Pi 5 (on the signal head floor) · I²C · 32 x 24 temperatures at 2 Hz

5. 

   05

   Bay radar

   In the bay-side wall, 40 degrees down: people at the bay mouth behind the reversing truck and in the bay near the loader

   Raspberry Pi 5 (on the signal head floor) · UART · Up to 3 targets with position at 10 Hz

6. 06

   Red, amber and green aspects with tone and horn

   Two light sticks behind each 200 mm aspect show the bay's calls; a piezo tone and a speaker horn sound from the floor of the head

   Raspberry Pi 5 (on the signal head floor) · One data wire (lights) + I²S (amp) + GPIO (piezo) · Aspect colour and flash, tone, horn

7. 07

   Secure element, tamper and fire-panel relay

   Every call signed; the tamper switch marks the log when the door opens; the relay gives a supervisory signal through the site's own listed monitor module

   Raspberry Pi 5 (on the signal head floor) · I²C + GPIO · Signatures, tamper flag, supervisory contact

8. 08

   Power, backup and LTE-M

   5 V from the light's own feed; a LiPo keeps the Walter board sending the heat alarm path and the log over LTE-M when the hall power is off

   Raspberry Pi 5 (on the signal head floor) · 5 V rail + UART to the brain · Power about 3.5 W watching, 7 W while tipping (est.); calls and the 5-minute log over LTE-M

9. 09

   All connected

   7 key parts, one program, and your phone

Our circuit board · rev A-0

One board of our own inside BayOne

Every chip on one board we design, shaped to fit: the processor, cameras and sensors, Wi-Fi and Bluetooth, lights, sound and power. No plugs, ribbons or adapters. It is checked in our CAD against every part around it, and it arrives from the maker ready to run our software from a microSD card. Turn the model, or pick a part below to see where it sits.

Demo · 6 real-world moments

See BayOne work

Short animated scenes of real moments: what happens today, what BayOne does about it, and what lands on your phone. The same scenes play in the IEMI app.

Demo scenes show how BayOne and its app are designed to behave. BayOne is in design; nothing here is recorded from real equipment yet.

The idea

The tipping bay's own traffic light checks every load, watches the pile for heat and keeps people out of the truck's way

How the parts connect

BayOne, wired up

Every part, what links it to the brain, and how the data reaches your phone. A solid line is a cable; a dashed line is a radio link.

The program

What controls BayOne

while True:
    targets = radar.read(); frame = cam_bay.frame()
    calls = bay_rule(person_model(frame), targets)   # green only when clear
    if truck.reversing():
        ticket = plate_model(cam_app.frame())
    if truck.tipped():
        calls += banned_rule(item_model(frame), heat.frame(), ticket)
        calls.append(load_grade(mix_model(frame), ticket))
    calls += hotspot_rule(heat.frame()) + smoke_rule(frame)
    if due(60):
        calls += pile_rule(frame)
    for c in calls:
        if c.conf < c.line: c.kind = 'check'   # never guess
        atecc.sign(c); aspects.show(c); uplink.send(c)
        if c.kind == 'hotspot': fire_relay.supervisory(True)
    time.sleep(0.1)

To your phone

How the data reaches BayOne bay app

Site manager, loader drivers, the on-call person at night and the commercial team; a web page for the office (Android, iPhone, web)

1. BayOne light
2. LTE-M (or the hall Wi-Fi, WPA3) · MQTT over TLS
3. IEMI cloud (the operator account)
4. Push, SMS and web; CSV and webhook export to the weighbridge and billing system
5. Site manager, loader drivers, on-call person and the office

Key specs

Targets for production units; they may change during development.

Pricing

Target pricing. Bought separately per bay: a plain 3-aspect bay light (about $650, est.), RecycleYard Hall ($2,490 + $119/month) and EmberWatch AI ($3,490 + $39/month): about $6,630 + $158/month (est.).

Indicative launch pricing in USD, excluding taxes and shipping. Final pricing is confirmed before any balance is charged.

1. 4 Nov 2026, 04:30LatestA transfer station or recycling site manager buys BayOne as the tipping bay's own 3-aspect traffic light, on the push wall end, on the light's own feed. So the electronics must be boards an assembly house makes and tests the same way every time, inside the same 300 × 260 × 860 mm signal head, seeing the whole bay and the yard, with nothing plugged together inside.

   • What we designed: boards of our own lining the walls of the signal head. An 8-layer main board lies flat on the head floor with the processor, a heat block to an aluminium plate bolted to the steel base plate, memory, the security chip, the microSD card with our software and the horn amp. A back strip holds the bay camera chip and the heat chip on small tabs looking down the bay; a radar strip holds the 60 GHz radar chip behind the bay-side radome; a tall front board behind the door carries 24 LEDs behind each aspect, the approach camera between the green and amber aspects, the LTE-M modem with a soldered eSIM and the Bluetooth module, their antennas in the door's solid top corners. A power board on the left wall keeps mains on its own: the supply, one soldered backup cell with its thermistor, and the relay to the site's fire panel. It replaces the Raspberry Pi 5, two camera modules, the heat-camera board, the radar module, six LED sticks, the LTE-M board and five other bought boards. See /build/bayone-boards
   • How we checked it: the boards are written as code and opened in KiCad (0 design-rule violations). The code places 120 parts at their sizes and checks each sits on its board inside the head, with no overlaps and room for its height; that each sensor tab, lens and chip sits 0.3 mm inside its wall; that every LED sits inside its 200 mm aspect; and that all 15 bay calls (the fresh load, a battery at the front, the far side of the tip, the 4 m line, smoke, the pile middle and corners, people at the bay mouth and near the loader, the fleet number, the next truck) are in view from where the chips really sit. The shared design review gives 17 pass, 2 fixed, 10 to prove and 0 fail: a gas bottle at the far side of the tip about 44 pixels across, a fleet-number digit about 31.
   • What we learned: from the bay-side wall, the pile against the near push wall lies 87 degrees off the wall, so no window there could show it. The bay and heat cameras now look out of the back wall, which faces down the bay, 45 mm from the bay edge so the push wall top does not hide the near corner; the radar slot and the approach window grew to the size our chips need. All drawn in the signal-head CAD in the same run, and all 15 CAD views still pass. The heat chip sees a 1 m hot patch at the back wall as about one pixel: enough for heat that keeps growing over minutes, and checked with a hot plate at 15 m on the first boards.
   • What is next: the boards inside the signal-head CAD with the heat plate, the tab brackets and the door magnet; LTE-M range in a steel hall; and the next board, PumpOne.

   See it in 3DFull research and design

2. 29 Oct 2026, 04:50A transfer station or recycling site manager needs people kept out of the way of reversing trucks, batteries pulled from loads before they burn, and pile heat watched through the night. Fires are rising: a 2026 NWRA and RRS report estimates more than 5,000 fires a year at US recycling facilities, and Fire Rover counted a record 448 reported waste and recycling fires in the US and Canada in 2025, with batteries the leading cause. Today a site buys a bay light, load checks and a roof thermal camera or a site-wide suppression system (about $200,000-235,500 plus $2,000-3,650 a month in council papers) separately.

   • Buyer check with sources: the 2026 NWRA and RRS fire report, Fire Rover 2025 fire count, the January 2026 NWRA, ReMA and SWANA battery guide, bay light prices ($316-345 for compact units), Fire Rover purchase and monthly fees from two council papers, and roof thermal cameras and belt vision as competitors
   • What we learned: the answers on offer are big site-wide suppression systems or cameras on the roof; nobody makes the bay light itself call people, loads and heat. BayOne is the early warning and bay controller under a suppression system, not against it
   • Parts list prices checked on the Adafruit pages today: $1,138 per bay at qty 1, of which $464 is our electronics; the 4 GB Raspberry Pi 5 is now $130, so the brain is the same-size 2 GB at $90, and the cameras cost more than we had
   • Price kept at $3,990 + $49 a month per bay; cost about $1,348 at qty 1 and $960 at qty 100, a 66 % to 76 % margin (est.) that funds model training and bay trials
   • All 21 part fit checks and 15 camera, heat and radar views in the CAD still pass; about 12 h of heat watch in a power cut rechecked; CAD review clean with no floating parts and no collisions
   • Product page: the first three FAQs answer why not a roof thermal camera or a suppression system, what it costs, and whether it fits the light already on site; a power and size spec group
   • Next: three questions for site managers in customer reviews (new head or a kit, which call matters most and whether insurers value the signed log, one bay or the whole hall), then RoadOne for public sector and roads

   See it in 3DFull research and design

3. 28 Oct 2026, 13:05A waste or recycling site needs one thing at each tipping bay that keeps people out of the reversing truck's way, catches batteries and gas bottles in loads, finds a pile hot spot before it becomes a fire and keeps piles under the permit line. Vehicle strikes are the biggest cause of worker deaths in UK waste (HSE figures reported by letsrecycle.com), the US EPA counted 245 battery fires at 64 facilities and calls it underreported, and the Environment Agency caps piles at 4 m and requires early detection; today operators buy load cameras, thermal fire watch and cab tags separately.

   • Market check: who buys one product per tipping bay (transfer stations, MRFs, recycling centres, scrap yards), the safety and fire case (HSE vehicle-strike figures, the US EPA battery fire report, the Environment Agency's fire prevention plan limits: 4 m high, 20 m long, under 6 months, early detection), what they pay separately and the competitors (Greyparrot, AMCS, Fire Rover); sources in DESIGN.md
   • New CAD: the bay's 3-aspect 200 mm traffic light (300 x 260 x 860 mm) on the push wall top, with a Raspberry Pi 5 brain, a bay camera and a heat camera looking down over the wall into the bay, a radar, an approach camera behind the door, call lights behind the three aspects, a tone and a horn, LTE-M, a backup cell, a fire-panel relay, a secure element and a tamper switch inside; 21/21 parts fit from datasheets, 15 camera, heat and radar views checked with a new test that the push wall does not hide them, no collisions, no floating parts
   • equipment.json: 10 rules met (pile height, length and age, detection, people and vehicles, same size, nothing over the bay, electrical, privacy, radio); 8 calls (6 alone), 4 impact cases and every security key
   • idea.json bay plan, integration.json (6 parts, 5 app screens with a No banksman at the bay mode), bom.csv (about $1,190 a bay with the plain head, est.), buy.json with 10 key parts
   • New product page at /products/bayone/ in Waste & Recycling: $3,990 + $49/month per bay against about $6,630 + $158/month bought separately (est.); folds RecycleYard and EmberWatch AI; ForkGuard Log (forklift cabs) and WasteSort Coach (office bins) stay listed; next: F18 Public sector, roads and airfields

   See it in 3DFull research and design

4. 28 Oct 2026, 13:05A waste or recycling site needs one thing at each tipping bay that keeps people out of the reversing truck's way, catches batteries and gas bottles in loads, finds a pile hot spot before it becomes a fire and keeps piles under the permit line. Vehicle strikes are the biggest cause of worker deaths in UK waste (HSE figures reported by letsrecycle.com), the US EPA counted 245 battery fires at 64 facilities and calls it underreported, and the Environment Agency caps piles at 4 m and requires early detection; today operators buy load cameras, thermal fire watch and cab tags separately.

   • Now part of BayOne: https://iemilabs.com/products/bayone/

   See it in 3DFull research and design

5. 28 Oct 2026, 13:05A waste or recycling site needs one thing at each tipping bay that keeps people out of the reversing truck's way, catches batteries and gas bottles in loads, finds a pile hot spot before it becomes a fire and keeps piles under the permit line. Vehicle strikes are the biggest cause of worker deaths in UK waste (HSE figures reported by letsrecycle.com), the US EPA counted 245 battery fires at 64 facilities and calls it underreported, and the Environment Agency caps piles at 4 m and requires early detection; today operators buy load cameras, thermal fire watch and cab tags separately.

   • Now part of BayOne: https://iemilabs.com/products/bayone/

   See it in 3DFull research and design

Smart equipment · legal on the field

BayOne is the tipping bay traffic light, made smart

It replaces the bay's plain signal head on the same push wall end, at the same height, on the same base plate and 230 V feed, with the same three 200 mm aspects that tell each driver when to reverse in and tip, with every part built in. Everything inside the plain 300 x 260 x 860 mm signal head: brain, bay and approach cameras, heat camera, radar, call lights behind the three aspects, tone and horn, LTE-M, backup cell, fire-panel relay, secure element and tamper switch. About +0.6 kg over a plain head of about 9 kg (est.); no mast, no roof-steel thermal head, no cab tags.