Core Platform

AI Autopilot

Name: AI Autopilot Platform
Brand: BRAINIALL

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 methodology: connect, learn, optimize.

+6%Throughput verified (Brasil Mineral #441)

$781KEstimated annual profit gain

25Days controlled pilot (Jan–Feb 2024)

AWSCloud infra via SoftwareOne partnership

How It Works

Four stages from integration to autonomous optimization.

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.

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.

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.

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.

Inside AI Autopilot

Sense → Mirror → Predict → Optimize → Act

A closed control loop that thinks ahead. The plant runs in real time; the AI experiments in a digital twin and only sends a setpoint to the control system when it improves quality and throughput inside the safe envelope.

Real-time data ingest

Sense

Reads thousands of signals per second from your DCS · PLC · SCADA · historian — flow rates, pressures, vibrations, ore composition, motor current. Existing OPC UA / Modbus / MQTT / OSIsoft PI links, no new hardware.

Live process digital twin

Mirror

A live model of your process — calibrated on your historian — tracks the plant in real time. The twin is where the AI experiments. The production line is never the test bed.

Multi-variable forecast

Predict

Specialist models project how throughput, recovery, grade, and energy will evolve under current conditions — minutes ahead. Detects drift before it shows up on a control chart.

Setpoint search inside the twin

Optimize

AI searches the safe operating envelope your engineers configured — per variable, per site — for the setpoint combination that maximizes quality and throughput. Thousands of simulated scenarios run on the twin per minute. The plant feels none of them.

Advised setpoints, on time

Act

Recommends setpoints to your control system at the right moment. The DCS / PLC decides whether to apply them. Operator sees the rationale on the dashboard. IEC 61508 SIS remains the authoritative fallback.

Integration

How AI Autopilot plugs into your plant

A 5-stage closed loop — from sensor to setpoint — built on protocols your plant already runs.

01
Physical Operation
Data is gathered directly from industrial process equipment — sensors, mills, flotation cells, pumps, CCD thickeners — across the plant.
02
Supervisory System
Data flows through your existing SCADA / DCS / PLC layer via standard industrial protocols — OPC UA, Modbus, MQTT, OSIsoft PI. No hardware changes, no production downtime.
03
Real-Time AI Processing
BrainiAll AI Autopilot streams the data through our cloud or on-premise AI engine, applies multi-variable ML models, and computes optimal setpoints — within an operating envelope your engineers configure per variable.
04
Monitoring Dashboard
Key metrics, recommended setpoints, anomaly flags, and performance trends are displayed on the operator dashboard for visibility and override when needed.
05
Closed-Loop Feedback
Autopilot sends setpoint adjustments back to the plant in real time. The equipment operates in cruise mode; the AI keeps learning from every new data point and adapts to ore drift, equipment wear, and operational changes.

Optimized for every stage of mineral processing

AI Autopilot has models tuned for the three highest-impact operations in mining: grinding, flotation, and leaching. Each covered by its own control logic, KPIs, and ROI model.

Grinding

Real-time optimization of SAG/ball mill power, speed, feed rate, and water addition. Maintains p80 target while maximizing tons per hour across ore hardness changes. Verified +6% throughput on hard ore in a Canadian gold mining pilot (Wi ≥ 14 kWh/t) — published in Brasil Mineral Magazine.

Flotation

Continuous tuning of collector dosage, frother rate, pH, air flow, and pulp level across rougher / scavenger / cleaner circuits. AI balances recovery vs grade non-linearly, accounting for ore mineralogy. Reduces reagent consumption while holding concentrate grade within spec.

Leaching

Predictive control of cyanide dosage, dissolved oxygen, retention time, and CCD thickener performance. AI forecasts recovery loss from chemistry shifts and pre-adjusts before extraction drops. Cuts reagent waste and stabilizes gold / copper recovery in heap and CIP/CIL circuits.

Sustainability — less waste per ton produced

Every +% throughput AI Autopilot delivers without a proportional increase in power, chemicals, or water is a direct reduction in environmental intensity per ton of concentrate. In the same 25-day Canadian gold pilot that produced +6% throughput, specific energy consumption (kWh/t) stayed essentially flat — the additional tonnage came without burning more energy. Stable operation means less reagent over-dosing, fewer upset conditions, and tighter water-balance control — measurable gains for both bottom line and ESG reporting.

~5%Typical reduction in energy consumption per ton

↓Reagent / chemical over-dosing cut by stable operation

↓Water waste minimized via tighter pulp density control

0Safety incidents attributable to AI in production deployments

Free Bottleneck Assessment — see where AI can unlock output

Our engineers analyze your plant data and deliver a data-backed report showing exactly where production is slowing, where capacity is being wasted, and what +% throughput Autopilot can unlock. No cost, no commitment — typical turnaround: 10 business days.

Request Free Assessment

See Live Demo

How It Works

Four stages from integration to autonomous optimization.