1.
Briefly explain your technology/solution exclusive for crane condition monitoring &
predictive maintenance. How does your technology differ from your fellow
competitors?
Our solution is a comprehensive AI + sensor-based Crane Monitoring Ecosystem that
covers multiple aspects of crane operation and predictive maintenance.
● Crane Position Monitoring System – Real-time tracking of LT & CT positions with
geofencing to prevent unsafe operation.
● Crane Control Panel Monitoring System – Monitors energy consumption and
detects anomalies like smoke and overheating.
● Hook Free Fall Detection System – Ensures safety by detecting sudden hook
drops.
● Hoist Health Monitoring System – Tracks thruster status, brake shoe wear, motor
temperature, vibration, and switch health.
● Motor Condition Monitoring System – Captures motor vibration, temperature, and
power data for predictive analysis.
● Crane Rail Monitoring System – Detects cracks, corrosion, and vertical
misalignment using specialized sensors, AI-based image processing, and encoder
feedback.
Differentiators from competitors:
● End-to-end coverage of all critical crane components, not just a single subsystem.
● Real-time AI-based analysis with automated alerts.
● High-accuracy rail monitoring with sensor + encoder integration.
Modular and scalable deployment that adapts to different crane sizes and industries.
2. What types of faults/defects are detected in a crane system or
subsystems & components such as motor, gearbox, pulleys, ropes,
hoist, hook etc.?
Our system detects faults across multiple subsystems:
● Motors/Gearbox: Overheating, abnormal vibration, lubrication failure.
● Ropes & Pulleys: Fraying, tension imbalance, misalignment.
● Hooks: Surface cracks, wear, deformation.
● Electrical: Overcurrent, voltage fluctuations, insulation breakdown.
● Brakes & Hoist: Brake pad wear, slip detection.
3. What is the level of accuracy of detection of faults? How early can you
detect the faults?
Our AI-based crane rail monitoring system continuously captures high-resolution images
from HGC sensor modules and processes them in real time. This allows us to detect
anomalies such as cracks, misalignment, and vibration-related irregularities as soon as they
occur, enabling immediate alerts to the maintenance team.
While we are not specifying a fixed numerical accuracy level at present, our real-time
detection mechanism ensures that faults are identified at the earliest possible stage,
minimizing operational risks and preventing progressive damage. The system’s performance
is continuously improving as the AI model is trained on more operational data.
4. Can your monitoring system operate in harsh (high temperature,
humidity, dust, etc.) industrial environments?
Our monitoring system is designed keeping industrial conditions in mind. The sensors and AI
camera modules can be enclosed in protective housings to safeguard against dust, humidity,
and temperature variations. For harsher environments, the system can be customized with
industrial-grade enclosures (IP-rated), cooling/heating options, and vibration-resistant
mounts. This ensures reliable operation even in challenging conditions.
5. Can your system integrate with existing PLC? Is it hardware agnostic?
Our system is designed to be hardware-agnostic and flexible for integration. While we
haven’t yet implemented it with industrial controllers, the architecture supports standard
communication interfaces, so it can be integrated if required.
6. What is the typical response time from anomaly detection to alert
generation, and how is the alert communicated?
Our system is designed to provide near real-time response once an anomaly is detected,
typically within a second under normal conditions.
Alerts can be configured in multiple ways, such as:
● Audible alarms at the crane site,
● Notifications via SMS or Email,
● Updates on a cloud-based dashboard with maintenance logs.
We have tested these methods in our prototypes, and the same setup can be extended or
customized as per industrial needs.
7. Do you support predictive maintenance, and if so, what is the typical
lead time for failure prediction?
Yes, we are working towards enabling predictive maintenance as part of the system. The
approach uses AI-based trend analysis of parameters like vibration, temperature, and
encoder logs.
The actual lead time for failure prediction depends on the type of component, operating
conditions, and amount of historical data available. In general, such systems are capable of
providing early warnings ranging from a few days to several weeks in advance, but we are
still in the process of validating these results in real industrial scenarios.
8. Can your system differentiate between mechanical, electrical, and
structural faults?
Our system is designed to differentiate between different categories of faults by combining
sensor data and AI analysis.
● Mechanical issues can be indicated by vibration patterns, encoder mismatches, or
pulley behavior.
● Electrical irregularities may be reflected through current/voltage variations or
thermal changes.
● Structural concerns such as rope wear, cracks, or surface deformation can be
identified using vision-based inspection.
We are still in the process of validating how accurately these distinctions can be made in
real-world industrial environments, but the framework is in place to support such
differentiation.
9. Is your solution compatible with different crane types (e.g., tower,
gantry, overhead)?
Our solution is currently focused on EOT (Overhead Traveling) cranes, where we monitor
rope condition, hoist behavior, and hook wear. The architecture, however, is modular and not
restricted to a single crane type. With suitable condition-specific adaptations, the same
approach can be extended to other cranes such as tower or gantry cranes in the future.
While we have not yet deployed on these, the system design allows for easy scaling across
different crane categories.
10. Can your system be retrofitted onto existing cranes, or is it designed
for new installations only?
Our system is designed to be retrofittable on existing cranes without requiring major
structural changes. The sensors and modules can be mounted on current setups with
minimal downtime. At the same time, the solution can also be integrated into new crane
installations as part of a fresh deployment. While our present work is focused on retrofitting
EOT cranes, the approach can be scaled to both existing and new systems as needed.
11. Do you have partners in India, or do you collaborate with partners to
implement solutions?
Yes, we collaborate with system integrators and crane OEMs in India for deployment and
service support. Partnerships include industrial automation vendors for PLC/SCADA
integration.
12. Could you provide a 1-page overview of your optical inspection
solution/technology?
Yes, we can provide a detailed 1-page technical brief showing:
● AI-based vision module for rope & hook inspection.
● Integration with encoder mapping for defect localization.
● Cloud dashboard visualization.
13. Would you be willing to present your Crane Health Monitoring to Tata
Group Companies in a virtual session?
Absolutely. We would be glad to present our technology in a virtual session to Tata
Group colleagues and demonstrate the live monitoring dashboard along with case studies.