Built for the cranes
you can’t afford to
lose.
Crane AI Shield catches faults while your duty-cycle cranes are under load — and gives the operator the fix before the bay goes down.
Globally
Downtime Saved
Acted Upon
Cost
Cost
Throughput
*Note – Date as of June 03, 2026 Source – PlantOS™ Digital Reporting System – User-validated True Positives & False Negative Rate
Standard predictive maintenance was never built for cranes — so your most critical asset runs blind.
A crane behaves nothing like the steady-state machines PdM was designed to watch.
It wakes a few times a day
Sparse battery snapshots. The fault surfaces between samples — and never gets recorded.
We listen at the right moment
RPM tracked live; vibration captured only at stable speed. Zero false alarms.
It goes quiet under load
Sensors stop reading the moment the crane works — exactly when faults emerge.
Always-on monitoring
RPM and temperature stream 24/7. No blind spots — faults caught as they emerge.
It dies in foundry heat
Sealed battery units degrade under heat, dust and vibration — failing before the warning lands.
Built for the toughest floors
Engineered to survive where battery sensors fail.
One ignored fault doesn’t stay one fault.
A missed bearing signal cascades through the whole drivetrain — and the bay goes with it.
Watch a crane the way a crane behaves — always-on and Mechanical + Process context-aware — or you’re not managing reliability. You’re hoping.
One crane flagged. Four screens later, a validated fix.
No spectra to read, no dashboards to decode. The screen tells the operator what to fix — one tap confirms it held. That’s the 99% Trust Loop, live on the floor.
See the crane that needs you — and the exact part, already named.
No hunting through trends or spectra. PlantOS™ ranks every duty-cycle crane and surfaces one motor, on one hoist, at the top of the list.
Read the fix in plain words, not a vibration chart.
Motor velocity is trending up to 25 mm/s. The screen prescribes re-tightening the fixing locations — and shows the reasoning behind the call.
Confirm the fix held — in two taps.
Mark the action done, answer one question (did it predict the fault?), and the hours saved are logged straight against the asset.
Watch the alert turn green — and the model gets sharper.
The motor clears, the prescription closes, and every confirmed outcome feeds the 99% Trust Loop — making the next call more certain.
Two Systems. One Unified Solution.
The hoist lifts. The long-travel moves. Each fails in its own language — Crane AI Shield reads both.
Every EOT crane runs on two motor systems — the long-travel that moves it across the bay, and the hoist that lifts the load — and Crane AI Shield monitors both.
| Long-Travel System | Main Hoist Drive | |
|---|---|---|
| Role | Moves the entire crane along its rails | Lifts and lowers the load — ladles, slabs, coils, scrap |
| Motion | Horizontal positioning across the bay | Vertical lift under shock load |
| Monitors for | Bearing defects · Lubrication degradation · Wheel-side looseness | Gear-mesh defects · Bearing degradation · Speed-correlated anomalies |
| If it fails |
Crane stranded mid-bay, positioning lost
Crane Wheel
GB Crane Wheel
GB Crane Wheel 1
Crane Wheels
|
Suspended-load risk, forced bay stoppage
Left Side Support Bearing
Right Support Bearing
Main Hoist Motor (DE-NDE)
|
Hardware and AI — Engineered Together.
Sensors that outlast the foundry floor. AI trained on 3.3 billion real-plant data points. Engineered as one system — so the prediction holds up where lab-built tools fail.
Crane AI Shield isn't a sensor and a model bolted together — the hardware proven over 8 years in the field and the AI trained on real production data are engineered as a single system.
| The Hardware8 years in the field | The AI in PlantOS™trained on production data | |
|---|---|---|
| Engineered for | The foundry floor — IP68 SS316 sensors and 180 °C-rated cabling that survive where battery sensors burn out | Real plants, not the lab — 3.3B+ data points and 99.97% prediction accuracy that sharpens with every closed work order |
| What it delivers | One rugged node captures RPM, temperature, and 3-axis vibration | Prescriptive work orders — which bearing, which gear, which shift to schedule it |
| In the field | Reconfigure remotely — tune sampling and thresholds from the cloud, no truck rolls | 24/7 monitoring with an Infinite Uptime expert on demand |
PlantOS™ — one unified system, one contract, one outcome: predictable uptime.
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