AI Assistant for Automation

The machine expert,
onboard the machine.

LinePilot is a local, 100% offline AI server installed directly on the production line. It answers in natural language — by voice or in chat — the questions of operators and engineers about the process, components, technical manuals and fault diagnosis.

Request a demo See how it works
  • Zero cloud
  • Zero data leaving the site
  • Voice + chat
  • Multilingual
OP
Operator · 11:41
The press won't move
AI
LinePilot · 11:41
Status read from the PLC
AQ3/i_AbilPress Pressure enable / exclude selector +AQ3 FALSE
AQ3/o_KM_pompa Lubrication pump motor contactor command +AQ3 FALSE
AQ3/o_EV_Pres Pressure engagement solenoid valve command +AQ3 FALSE

PRESS SOLENOID VALVE — 340Y2 (solenoid valve)

  • Panel +AQ3 · sheet 340 (page 92)
  • Command: PLC output %Q212.3 (module 210A4)
  • Connections: terminals X4 · power supply 0DC
Diagnosis

PLC output %Q212.3 is FALSE — the actuator is not receiving the command. Interlocks NOT satisfied:

  • Pressure enable selector (%I212.6) = FALSE → TRUE required
  • Lubrication pump contactor (%Q212.0) = FALSE → TRUE required
  • also to be checked: M_PORTA_OK, M_EMERG_OK (guards, emergencies)
Suggested checks
  1. Set the pressure enable selector to ON and check its contact — Procedure: §18
  2. Check the lubrication pump contactor — Procedure: §14
  3. Check guards and emergencies (doors closed, e-stops reset)
⚠ Before operating apply LOTO (Section 0) and make sure the area is clear and safe.
Documents consulted
EM310045_rev04.pdf · p. 92

Component identified from the wiring diagram, I/O status read in real time from the PLC, diagnosis of the missing interlocks and verification procedures. With the sources cited, always.

OP
Operator · 09:17
I have a problem at the outfeed, I suspect it's the end-of-line photocell: could you tell me the brand and model so I can check if I have it in stock?
AI
LinePilot · 09:17
Status read from the PLC
AQ1/i_FTC_fineln End-of-line photocell, part present at the outfeed FALSE

END-OF-LINE PHOTOCELL — B12 · Sick WL12G-3B2531 · stock code EL-0417

  • Panel +AQ1 · sheet 118 (page 31)
  • PLC input %I3.4 (module 110A2)
  • Connections: terminals X2:14 (signal) · X2:15 (24VDC) · X2:16 (0V)
Signal check
  1. Block and clear the beam: the yellow LED on the photocell must switch and input %I3.4 change state — Procedure: §7 (Checking a PLC digital input)
  2. If the LED does not switch, clean the optics and the reflector and check the 24VDC on terminals X2:15/X2:16
  3. If the signal is still absent, perform the alignment — Procedure: §25 (Photocell adjustment)
Documents consulted
Manuale_linea.pdf · p. 42
Schema_elettrico.pdf · sh. 118

Brand, model and stock code from the bill of materials, connections from the wiring diagram, live reading of the PLC input and adjustment procedure. With the sources cited, always.

OP
Operator · 09:51
The infeed pump won't start
AI
LinePilot · 09:51
Status read from the PLC
AX7/i_th_Pompa1 Motor-protection circuit breaker, main tank pump 1 TRUE
AX7/o_KM_Pompa1 Tank pump 1 motor contactor command FALSE

INFEED PUMP — 1.1 KW / 2.66 A — 372M1 (motor)

  • Panel +AX7 · sheet 372 (page 108)
  • Connections: terminals X2:1, X2:2, X2:3 · power 2U1, 2V1, 2W1, PE

INFEED PUMP OVERLOAD (auxiliary contact 13-14) — 372Q1 (circuit breaker)

  • Panel +AX7 · sheet 372 (page 108)
  • Signal: PLC input %I218.2 (module 215A3) = TRUE
  • Connected to: 372KM1 (contactor 24VDC 3KW 1NO)
  • Spare part code: SIE.3RV2011-1DA10 (Siemens)

CONTACTOR 24VDC 3KW (1NO) — 372KM1 (contactor)

  • Panel +AX7 · sheet 372 (page 108)
  • Command: PLC output %Q218.5 (module 215A5) = FALSE
  • Connected to: 372Q1 (infeed pump overload, contact 13-14)
  • Spare part code: SIE.3RT2015-1BB41 (Siemens)
Diagnosis

The motor-protection circuit breaker is closed (%I218.2 = TRUE), but the command output %Q218.5 is FALSE: contactor 372KM1 is not energized and the motor is not receiving power.

Suggested checks
  1. Check the state of digital output %Q218.5 on the PLC — Procedure: §11
  2. Check contactor 372KM1 (energization and contacts) — Procedure: §21
  3. Measure the voltage at the terminals of motor 372M1 — Procedure: §2
⚠ Before every check, isolate and make safe (LOTO). Work on the electrical panel: qualified personnel only.
Documents consulted
Schema_elettrico.pdf · sh. 372 · p. 108

Actuator identified from the wiring diagram, I/O status read in real time from the PLC, diagnosis of the missing command and verification procedures. With the sources cited, always.

Why LinePilot

Knowledge doesn't retire

The line's know-how lives in dozens of manuals and diagrams and in the heads of a few experts. LinePilot makes it queryable by anyone, on any shift, in any language.

Shorter machine downtime

Guided diagnosis in seconds instead of hours leafing through PDFs: brand, model and spare part code of the right component, with the history of similar interventions.

Your data stays in the factory

No cloud, no external API: LLM, semantic search and voice run entirely on the server onboard the machine. It works even without an internet connection.

Features

🔌 100% offline

Everything local: language model, embeddings, speech recognition and synthesis. No data ever leaves the plant.

🎯 Never invent a code

LinePilot answers only from your line's documents and states when it doesn't know. A wrong spare part code is costly: that doesn't happen here.

📄 Sources always cited

Every answer indicates the source document and page: verifiable in one click.

🎙️ Hands-free voice

Speak and listen: speech recognition and synthesis, designed for use on the line with gloves on.

⚡ Answers in seconds

Response streaming and a search indicator: designed for production timing, not office timing.

📚 Multilingual manuals

Datasheets in English, manuals in German, SOPs in Italian: LinePilot indexes them all and answers in the operator's language.

🔌 PLC connection

Direct connection to the line PLC in read-only: LinePilot sees the real state of inputs and outputs, without ever writing and without interfering with the machine cycle.

📈 Real-time diagnosis

It cross-references the PLC software logic with the live I/O status: it pinpoints the missing interlocks and tells you why an actuator won't start, while the fault is happening.

🔗 Connection to the company ERP

Optional integration with the management system for the spare-parts warehouse: stock level and location of the component directly in the answer, always on the local network.

How it works

  1. 1

    Ask a question

    In chat or by voice, as you would ask an expert colleague. Even complex questions that span multiple documents.

  2. 2

    Get the answer with the sources

    LinePilot retrieves the relevant passages, links manual, diagram and bill of materials, and answers citing document and page.

  3. 3

    Process and live data too

    It also answers about the production process and, with the optional connections, about the I/O status read from the PLC and the availability of spare parts in the warehouse (ERP).

Technology

Generative artificial intelligence that runs entirely onboard the machine, on dedicated industrial hardware. No cloud license, no recurring cost per token, no data leaving the plant.

Local generative AILanguage models run on the line server
Semantic searchFinds the answer in the manuals and diagrams by meaning, not by exact word
Offline voiceSpeech recognition and synthesis without cloud
HardwareIndustrial server with dedicated GPU, in different sizes according to the complexity of the plant
NetworkPlant LAN only, internet not required
Optional integrationsPLC connection for reading I/O status · offline PLC program · spare-parts warehouse (ERP)

Bring LinePilot to your line

Tell us about your production line: we'll prepare a demo with your real documents.

or write to us at info@linepilot.it