BrainPredict™ AutomationEnterprise AI Operating System for Industrial Automation
Connect OTTO to any industrial OT device — PLC, DCS, SCADA, historian — via universal OPC-UA subscription or Modbus TCP. 31 AI models turn live process data into actionable intelligence across all 19 BrainPredict™ platforms. Now includes the OTTO Plain-Language Code Writer, AIIC Cascade Engine, and BLO Autonomous Code Remediation. 100% on-premise. Zero cloud dependency. Compliance by design.
How BrainPredict™ Automation Works
Three layers — no proprietary hardware, no cloud dependency, no vendor lock-in.
Layer 1 — Protocol Adapters
- OPC-UA MonitoredItem Subscription (not polling)
- Siemens S7-1500, ABB 800xA, Emerson DeltaV, Honeywell Experion, Yokogawa CENTUM VP, Mitsubishi iQ-R, Beckhoff TwinCAT, GE iFIX, AVEVA PI, Ignition SCADA
- Modbus TCP — Schneider M340/M580, Owen PLC
- Basic256Sha256 security, certificate auth, triple-gate write-back
Layer 2 — AI Intelligence
- 31 AI models on live process data
- OTTO Plain-Language Code Writer — IEC 61131-3 ST/LD/FBD from natural language
- AIIC Cascade Engine — 19-platform fan-out in <500ms on any safety event
- BLO Autonomous Code Remediation — auto-generates PLC fix programs
- Setpoint Recommender — constitution-bounded optimisation
- Anomaly detection at tag level (<500ms)
- Predictive maintenance 2–8 weeks ahead
Layer 3 — OTTO Intelligence
- Natural language queries in 30+ languages
- "What is OEE on Line 3?" — answered from live PLC data
- AI-generated shift handover reports
- Decision Cards for every setpoint recommendation
- Sentinel Safety OS governs every write-back
31 AI Models
Every model runs on-premise. No data leaves your network.
OPC-UA Intelligence Core
Subscription-based real-time tag monitoring across Siemens, ABB, Emerson, Honeywell, Yokogawa, Mitsubishi, Beckhoff, GE, AVEVA — XGBoost anomaly detection
Modbus Process Intelligence
Schneider M340/M580 and legacy PLC process variable monitoring — FLOAT32/INT16 register decoding + Prophet forecasting
Setpoint Recommender AI
Constitution-bounded setpoint optimisation toward nominal — deviation-from-baseline heuristic + confidence scoring
OEE Predictor (OT)
Real-time OEE prediction from live PLC tags — XGBoost + LSTM on availability, performance, quality signals
Predictive Maintenance OT
Equipment failure prediction 2–8 weeks ahead from vibration, temperature, current tags — XGBoost + survival analysis
Energy Optimiser
AI setpoint recommendations to minimise energy consumption while maintaining throughput — reinforcement learning
Alarm Intelligence Engine
Nuisance alarm identification, alarm flood prediction, ISA-18.2 rationalisation — BERT + rule engine
Process Quality AI
Real-time SPC from OPC-UA tag streams — XGBoost + Shewhart control chart automation
Tag Anomaly Detector
Sub-second anomaly detection on OPC-UA MonitoredItem pushes — Isolation Forest + Z-score
Process Baseline Engine
Statistical baseline computation (mean, 2σ, percentiles) from 30-day rolling tag history — scipy stats
Industrial Digital Twin
Real-time asset state mirror from OPC-UA/Modbus streams — graph-based twin with AVEVA/Microsoft ADT integration
Throughput Optimiser OT
Multi-line production throughput optimisation using live PLC data — genetic algorithms + constraint solver
Safety Interlock AI
Pre-emptive safety condition prediction from process tags — XGBoost on IEC 61511 safety instrumented function signals
Vibration Analyser
FFT-based vibration signature analysis for rotating machinery — bearing fault, imbalance, misalignment detection
Temperature Pattern AI
Thermal runaway and heat exchanger fouling prediction from temperature tag arrays — LSTM time-series
Flow Optimiser
Piping and valve flow optimisation using differential pressure and flow meter tags — physics-informed neural network
Motor Health Monitor
Motor fault prediction from current, speed, temperature tags — Park vector analysis + XGBoost
Process Batch Predictor
Batch end-point and quality prediction from in-process tags — LSTM + XGBoost ensemble
Valve Position AI
Valve stiction and hysteresis detection from position feedback — signal processing + XGBoost
Compressor Intelligence
Compressor surge prediction and efficiency optimisation from flow/pressure/speed tags — physics model + ML
Heat Exchanger Fouling AI
Fouling factor estimation and cleaning schedule optimisation — heat transfer model + XGBoost
Reactor Stability AI
Reactor temperature and pressure stability prediction — nonlinear model predictive control + XGBoost
Production Schedule Optimiser
Real-time production schedule adjustment based on live OEE and constraint data — mixed-integer programming
Shift Handover Intelligence
AI-generated shift handover reports from tag deltas and alarm history — SLM v2 13B NLG
Regulatory Compliance Monitor
IEC 62443 / ISO 13849 / NIS2 compliance monitoring from process and audit data — rule engine + BERT
Connector Health Monitor
IT/OT connector latency, error rate, sync lag monitoring — statistical process control on connector metrics
Cross-Domain Intelligence Bridge
Routes OT insights to Finance, Supply, Controlling, Risk platforms via Intelligence Bus v6 — event routing + ML classification
Automation Audit AI
Dilithium-3 signed audit trail analysis and compliance gap detection — BERT + regulatory knowledge base
OTTO Plain-Language Code Writer
Converts plain English into validated IEC 61131-3 ST/LD/FBD programs — SLM v2 CODE_INTELLIGENCE + automation LoRA adapter. Siemens, Schneider, Beckhoff, Rockwell, OMRON vendor headers generated automatically.
AIIC Cascade Engine
Autonomous Industrial Intelligence Cascade: any otto.automation.* safety event fans out to all 19 BrainPredict platforms in <500ms p95 via asyncio.gather. Unified Decision Card with Dilithium-3 signature.
BLO Autonomous Code Remediation
BrainPredict Living Organism detects automation issues and automatically generates the IEC 61131-3 remediation program — validated, Digital Twin simulated, presented as Decision Card. Deployed via Sentinel on operator approval.
Compliance by Design — Not Configuration
Sentinel Safety OS enforces every regulation listed below at runtime. There is no compliance mode to enable — it is structural, present in every deployment from day one.
Generated programs validated against all structural, syntax and safety rules
Industrial cybersecurity — authentication, least privilege, zone separation
Functional safety SIL — tamper-proof audit, human override always available
Safety of machinery PL d — e-stop reachable, restricted write to actuators
Human oversight — Decision Card required for every setpoint write and PLC program deployment
Risk management — Sentinel 5-layer gate on all OT write-back
Automated decisions — human approval mandatory before execution
Post-quantum signature on every deployed program, Decision Card, and audit log entry
Triple-gate: connected + sentinel_cleared + whitelist (all three required)
Triple-Gate Write Safety (BP_AUTOMATION)
Every setpoint write requires simultaneously: ① adapter.is_connected == True → ② sentinel_cleared == True (set by Sentinel Safety OS only, never by the user) → ③ tag_id in writeable_tags whitelist → ④ Decision Card approved by named human operator → ⑤ Dilithium-3 signature on execution. Any single gate failure blocks the write. This is not configurable.
Implementation Roadmap
Intelligence Overlay
OPC-UA + Modbus read-only. OTTO queries any device in natural language. Zero operational risk.
Predictive Operations Dashboard
Live process view with OEE, alarms, energy, production KPIs from OPC-UA/Modbus. AI-generated shift handover reports.
Closed-Loop Recommendations
AI recommends setpoint changes → Decision Card → human approves → triple-gate write → Dilithium-3 audit.
Plain-Language Code Writer
Type what the PLC should do — OTTO generates a complete IEC 61131-3 program (ST/LD/FBD), validates it, tests it in the Digital Twin, then presents a Decision Card. One click to deploy via Sentinel.
AIIC — Cross-Platform Cascade
Any automation safety event fans out instantly to all 19 BrainPredict platforms in <500ms. Finance flags ERP, Supply raises emergency PO, People dispatches technician, Cyber checks OT boundary — simultaneously.
BLO Autonomous Code Remediation
BrainPredict Living Organism detects the root cause, generates the IEC 61131-3 fix program, validates it, simulates in Digital Twin, and presents a single Decision Card. Operator approves — Sentinel deploys.
Autonomous Supervision
Pre-approved Enterprise Constitution response rules execute automatically. All others escalate as Decision Cards.
Connect your first OT device today
Platform #19 — €3,999/month. On-premise. Full source access. No SaaS fees.
Request ImplementationIntelligence Layer — Cross-Platform Enhancements
The PL4 Intelligence Layer adds the following cross-platform capabilities to this platform via the Intelligence Bus v8 — no separate deployment required.
OT Anomaly → Business Cascade
OT anomalies detected by the Automation platform cascade to Operations, Finance, and Supply in <500ms — the OT/IT bridge in action.
OT Signals in C-Suite Feed
Critical OT incidents surface in the COO and CEO daily feed, EUR-ranked by production and revenue impact.