Crane AI Shield · An Infinite Uptime Innovation

Your crane's worst fault is developing right now. You're not seeing it.

Crane AI Shield captures data at stable RPM — the only moment that matters. 19 failure modes. Zero false alarms. Purpose-built for steel, aluminium, and mining cranes.

946 Plants
Digitalized

157,115 Hours
Saved

99% Prescriptions Acted On

Crane AI Shield IoT vibration sensor mounted on heavy-duty motor housing in plant

Crane AI Shield Sensor Active: Motor & Gearbox Live Monitoring

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What Crane AI Shield Catches

Bearing seizure on the main hoist

the motor bearing turns quietly inside a sealed housing through 300–400 lift cycles a shift. By the time it's audible, it's already gone.

Gearbox failure under load

standard sensors stop recording exactly when the crane is stressed. Gear mesh faults emerge at peak torque — invisible to time-based sampling.

Lubrication collapse before it's visible

vibration energy can rise 40× in a single week with no thermal or acoustic symptom. A re-lube that costs minutes gets missed until it costs a motor.

How Crane AI Shield Works

RPM-triggered capture

Dynamic monitoring algorithm fires only at stable speed intervals. This eliminates heavy operational acceleration and deceleration noise entirely, delivering ultra-clean vibration data.

Full drive-train coverage

19 failure modes tracked in parallel — mechanical and gear faults across motor, gearbox, and rope drum.

Prescriptive work orders

No abstract graphs or alarm codes for plant engineers to decode. Instead, PlantOS™ issues explicit prescriptive directives: what tool to use, when to fix it, and the precise mechanical logic why.

Closed-loop validation

Every corrective maintenance task logged is verified. Closing a work order logs physical performance changes directly back to our models, sharpening the next diagnostic cycle.

Proven Industrial Impact

90 Days

Advance Detection Window

4 Hours

Unplanned Downtime Saved / Incident

97%

Average Vibration Reduction

EOT Crane Bearing

90-Day Warning Prevents Major Hoist Bearing Failure

A steel melt-shop EOT crane spent 90 days building toward a main hoist bearing failure with no operational symptom. PlantOS™ read the acceleration trend from 35 to 190 (m/s²)², issued the prescription on December 29, 2025. Relubrication was completed February 3, 2026 during a planned window. No unplanned stop. No bay outage.

Main Hoist Bearing Acceleration Trend DE Bearing Analysis