AI Autopilot
The intelligent control layer that monitors, predicts, and continuously optimizes your entire operation in real-time.
Brainiall AI Autopilot replaces manual tuning with AI that never sleeps. Traditional automation relies on static rules set by engineers who cannot monitor hundreds of variables simultaneously. Autopilot uses machine learning to map the complex, non-linear relationships between process variables and dynamically adjust setpoints — maximizing production value around the clock.
The platform sits on top of your existing control infrastructure — DCS, PLC, SCADA — reading thousands of sensor signals per second and writing optimized setpoints back through secure OPC connections. There is no hardware to install, no production downtime during deployment, and no disruption to your operators.
Designed for operations from SAG mills to flotation circuits, Autopilot delivers measurable throughput and efficiency gains across multiple commodities and processing methods. Every deployment follows the same 2-week methodology: connect, learn, optimize.
<200msControl loop latency
2 WeeksFrom kickoff to live results
5-10%Typical throughput gains
< 6 MonthsTypical payback period
How It Works
Four stages from integration to autonomous optimization.
01
Connect
Integrates with your existing DCS, PLC, and SCADA infrastructure. No hardware changes, no production downtime. Edge connectors read data in real-time from any industrial protocol.
02
Learn
The AI analyzes your historical and live operational data to build a multi-variable process model. It identifies hidden correlations, optimal operating windows, and constraint boundaries.
03
Optimize
Autopilot continuously adjusts process parameters to maximize throughput, minimize energy consumption, and prevent disruptions. Every setpoint is updated in real-time as conditions change.
04
Evolve
The platform continuously retrains its models with new data. As your ore body changes, equipment ages, or operating conditions shift, the AI adapts automatically to maintain peak performance.
Key Features
Enterprise-grade capabilities designed for mission-critical industrial environments.
Real-Time Monitoring
Unified dashboard with live telemetry from every sensor and actuator across your operation. Custom alerts, trend analysis, and KPI tracking at a glance.
Predictive Analytics
Forecast equipment failures, process drift, and quality deviations hours before they impact production. Reduce unplanned downtime by up to 30%.
Autonomous Tuning
Continuously adjusts hundreds of setpoints simultaneously to keep your process at the optimal operating point. Goes far beyond what manual control or basic PID loops can achieve.
Anomaly Detection
Machine learning algorithms flag abnormal sensor readings, equipment behavior, and process deviations in real-time. Catch problems before operators notice them.
Digital Twin
A virtual replica of your operation that enables safe what-if scenario testing, operator training, and process optimization without risking real production.
Multi-Variable Optimization
Simultaneously optimizes dozens of interrelated process variables that human operators cannot manage holistically. Finds the global optimum, not local peaks.
Applications
Flexible deployment models tailored to your operational needs.
Plant-Wide Optimization
Orchestrate all unit operations from crushing through to final product. The AI balances throughput, recovery, and energy across the entire flowsheet for maximum economic value.
Single Unit Operation
Focus on one critical bottleneck — a SAG mill, flotation bank, or leach circuit — and extract maximum performance from that single process area with targeted AI control.
Multi-Site Deployment
Deploy Autopilot across multiple mines and processing plants from a single centralized command center. Compare site performance, share learnings, and standardize best practices.
Native Integration
Autopilot connects to your existing infrastructure without hardware changes. We support every major industrial control system, data historian, and communication protocol.
Control Systems
Siemens PCS 7ABB Ability 800xAHoneywell ExperionEmerson DeltaVRockwell PlantPAxYokogawa CENTUM
Data Historians
OSIsoft PIAVEVA HistorianGE ProficyHoneywell PHDAspenTech InfoPlus.21
Protocols
OPC UAOPC DAModbus TCPMQTTREST APIProfinet
Safety & Operator Control
The AI suggests. The control system decides. Every deployment preserves your existing safety architecture.
Operator Override Always Available
Human operators retain full control at all times. One click returns any parameter to manual mode. The AI assists — it never overrides human judgment.
Setpoint Constraints
Min/max boundaries configured per site and per variable. The AI optimizes within safe operating envelopes defined by your process engineers — never outside them.
Automatic Fallback on Anomaly
If the AI detects anomalous sensor readings or unexpected process behavior, it automatically reverts to manual control and alerts the operator. No intervention required.
Full Audit Trail
Every AI decision is logged with timestamp, input data, reasoning, and outcome. Complete traceability for compliance, incident review, and continuous improvement.
Safety Interlocks Preserved (IEC 61508)
AI writes to an advisory layer, not directly to safety PLCs. Your existing IEC 61508-rated Safety Instrumented Systems (SIS), emergency stops, and critical alarms remain untouched and fully independent — Brainiall does not replace certified functional safety.
Advisory Architecture + IEC 62443 OT Security
The AI recommends optimal setpoints. The existing control system validates and executes. Network segmentation follows IEC 62443 principles with a read-mostly OT boundary and FMEA-based commissioning per site — the AI can never bypass safety logic or make unsafe changes autonomously.
Ready to put your plant on autopilot?
Get a free process assessment. Our engineers analyze your operation and show you exactly where Autopilot adds value — with projected ROI before you commit.