Software Solutions

Structural Health Monitoring - AI & Cloud Powered

The Structural Health Monitoring Solution continuously tracks the real-time health of industrial structures for structural load performance, independent of sensor type, by leveraging cloud-native capabilities and AI-driven analytics. Whether strain gauges, accelerometers, corrosion probes, vibration sensors, or IoT edge devices, the system ingests and harmonizes all sensor data into a unified platform.

Key Features

• Sensor-agnostic ingestion: Works seamlessly with any sensor type, protocol, or industrial IoT device

• Cloud-native architecture: Built on AWS services Cloud for scalable storage, query, and analytics

• LLM-powered insights: Large Language Models interpret sensor data, correlate with baseline FEA models, and generate human-readable narratives

• Conversational interfaces: Engineers and operators interact via chatbots and AI agents, asking natural language questions like “Show me stress anomalies in the crane beam last week”

• Predictive maintenance intelligence: AI agents forecast degradation trends, enabling proactive scheduling of interventions.

• Cross-industry support: Applicable to steel, concrete, composites, and industries such as manufacturing, power generation, shipping, and infrastructure

Solution Benefits

• Prevents unexpected failures and safety incidents through real-time anomaly detection

• Predictive vs reactive maintenance enabled by AI-driven forecasting

• Reduced inspection and maintenance costs by automating monitoring and analysis

Case Study – 850T EOT Crane Run-way Beam

• Sensor setup: Strain gauges, accelerometers, and vibration sensors placed at critical spans

• Baseline inputs: FEA data stored and compared in the Megha AI platform

• Dashboard visualization: Stress/deflection trends displayed in real time

• Automated alerts: Threshold exceedance triggered alarms and agent-driven recommendations

• Scalability: Model extended to monitor corrosion, fatigue, and structural integrity across multiple assets.

Equipment Vibration Analysis- AI-Powered, Cloud-Native, Sensor-Agnostic

Equipment Vibration Analysis solution ensures maximum equipment uptime through early fault detection and real-time maintenance orchestration. Built for the AWS ecosystem, it supports scalable, secure, and high-performance analytics across industrial assets.

Key Features

• Sensor-Agnostic Architecture: Compatible with MEMS, piezoelectric, wireless, and edge sensors

• Cloud-Native Deployment: Runs seamlessly on AWS for unified data warehousing

• LLM-Powered Insights: Natural language queries, chat-based diagnostics, and AI agent recommendations

• Real-Time Fault Detection: Automated alerts for imbalance, misalignment, looseness, and electrical anomalies

• Predictive Maintenance: Combines time-series, physics-based models, and AI for actionable foresight

• Digital Twin Integration: Real-time operational and IT data fusion for holistic plant visibility

Solution Benefits

• Reduced downtime and maintenance costs

• Improved equipment reliability and product quality

• Enhanced safety and decision-making for field teams

• Scalable across plants, assets, and sensor types

Case Study – One of the India’s largest Steel Manufacturing Plant

• Deployed vibration sensors across pump assemblies

• Data streamed via gateways using 4G router or equivalent to AWS cloud powered Megha AI platform

• Detected unsatisfactory vibration zone (6.38 mm/s) with harmonics

• AI agents recommended:

  • Inspect VFD harmonics

  • Verify coupling alignment

  • Check for looseness and foundation integrity

Cobble Prediction System- AI-Powered

Introducing the AI-Based Cobble Prediction System — a cutting-edge Megha AI solution designed to revolutionize operational reliability in steel rolling mills. Cobble events, sudden disruptions in the rolling process, can lead to costly downtime, equipment damage, and production delays. Our intelligent system empowers plant operators with real-time insights and proactive recommendations to stay ahead of risk.

Why Choose this Solution?

• Real-Time Monitoring: Continuously analyses live sensor data from speed, tension, temperature, vibration, roll position, roll age, and camber.

• AI-Powered Intelligence: Uses advanced pattern recognition, anomaly detection, and risk assessment algorithms to detect early signs of cobble formation.

• Actionable Alerts: Provides early warnings with countdown to event, risk level, and location-specific insights (e.g., Grade | Finishing Mill).

• Smart Recommendations: Suggests corrective actions like slowing down rolling speed or checking guide alignment to prevent escalation.

Key Benefits

• Minimize Unplanned Downtime: Avoid emergency stops and production losses.

• Enhance Safety: Reduce risk of equipment damage and operator hazards.

• Improve Yield: Maintain consistent throughput and product quality.

• Optimize Maintenance: Identify wear patterns and schedule proactive interventions.

Visual Dashboard Highlights

• Status Indicators: Clear visual cues for Normal Operation, Risk Alert, and Cobble Event.

• Live Sensor Feed: Transparent view of processing health and system stability.

Ideal For Steel and aluminium rolling mills, process engineers, plant managers, and digital transformation leaders seeking to embed predictive intelligence into their operations.

Case Study – One of the India’s largest Steel Manufacturing Plant

Cobble: A sudden strip breakage during rolling in the Hot Strip Mill, caused by process instability leading to production stoppage, equipment damage, and safety risk.

• Each HSM rolls ~200 coils per 8-hour shift (~25 coils/hour).

• A single cobble results in 1–3 hours downtime and losses running into a few tens of crores.

• Operators rely on manual judgment no real-time early warning (force, gap, torque, camber, temperature).

• MeghaAI predicts instability using AI and alerts operators in advance.

• Cloud-native AWS platform combining process data, domain rules & feedback.

• Major cost savings, higher uptime, stable rolling, improved safety, scalable multi-mill deployment.

Intelligent Design

Innovative software solutions for sustainable small and medium enterprises.