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.
This Is Crane AI Shield,
Catching What an
Inspection Can't.
A critical EOT crane at Tata Steel — 90 days of early warning, 04 hours of unplanned downtime eliminated, one scheduled fix.
A melt-shop EOT crane runs 300–400 lift cycles a shift. The main hoist motor carries every one. When its bearing drifts toward looseness, nothing trips and no operator notices — the crane just keeps lifting toward a seizure that stops the bay.
Crane AI Shield monitored both motor bearings continuously across vibration, acceleration, and shockwave domains. It read the rising signature 90 days out, prescribed the exact correction, and timed it into a planned window.
One planned stop, re-lube done on schedule. 04 hours of unplanned downtime eliminated. Vibration down 97% on the bay's highest-consequence asset.
See the full signal trend, diagnostics, and the verified outcome inside.
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.
Up and Running in 8 Weeks.
Six steps from the first site walk to active SLAs — on a fixed, predictable timeline.
Typical timeline — actual dates vary with crane count and site access. Hover over each step for details.
Ready to see Crane AI Shield read your crane?
Live walkthrough · your crane, your failure modes
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