Where it fits
Mining first — and inside mining,the water and coal that keep it moving.
Consystence started on a dam pump station and the coal handling plant beside it — centrifugal pumps on VFDs, motorised valves, belt conveyors, crushers and screens, fed from MCC sections. It was the first system we took end to end, from the PLC through the edge and site server to the cloud.
First proven on a dam pump station — the full PLC → edge → site → cloud chain.
Where it starts
Water and coal handling
Two processes a mine can’t run without — and the two we built first. Concrete equipment, real tags, shipped device types.
Prove duty/standby and start logic in simulation — before it ever drives a real pump.
A dam pump station moves the water the operation depends on. Consystence models it the way it’s built: centrifugal pumps on VFDs, motorised discharge valves, storage tanks, and the level, pressure and flow instruments around them — each a typed device with its own tags, alarms, commands and faceplate.
The MCC sections feeding those pumps are modelled too — a living electrical graph that generates the single-line diagram from the model, not a drawing, shows live load per feeder, and lets the AI trace the power path to any pump.
It was the first system we took the whole way — PLC to edge to site server to cloud — with closed-loop simulation standing in for the plant before logic touched the field.
Sequence the conveyor train and prove the blocked-chute and drive-fault trips in simulation — before they run a real plant.
Coal handling is materials handling at scale — belt conveyors and transfer chutes, crushers and screens, fed from MCC sections and driven by VFDs. The same library that runs the pump station covers the drives and conveyors that move the product.
Sequenced starts, blocked-chute alarms and drive-fault trips — modelled once as device types, rendered live to the operator on a screen they assemble on the fly.
What we proved
One site, the whole chain — end to end
Before any of it was a product, the full chain ran end to end on a single dam pump station — with closed-loop simulation standing in for the plant, before logic ever touched the field. Here's what that proved.
Every layer ran together — control logic on the PLC, the edge, the site server and the cloud — with the simulator in place of the plant. The whole stack, de-risked in one pass.
When the link to a remote station drops, the edge buffers every sample and forwards it when the link returns — store-and-forward, so the record closes up instead of dropping samples.
Every sample carries its source — measured, inferred, imported, simulated, replayed or workspace. The advisory AI reads the live and historian data to explain anomalies like early impeller wear — it never commands the pump.
Software only — skids and field commissioning stay with Deftec
Equipment library
An equipment library lifted from production code
Not a tag list someone hand-wired on site. Every piece of equipment is a typed device — and the types weren’t drawn on a whiteboard.
A device type is the unit of reuse. Like a Rockwell AOI or an Ignition UDT — but it carries its UI faceplate, its alarms, its simulation profile, and the context the AI needs to explain it. Define it once; deploy it everywhere with the same behaviour.
These types were distilled from production PLC code delivered to Tier-1 Australian miners over 20+ years — 112 UDTs and57 AOIs of proven control code. Thestandard library shipping today covers the equipment a pump station and a coal handling plant actually run on: pumps and drives, materials handling, and IO.
- Tags & data types
- Alarms with priorities & conditions
- Operator commands
- UI faceplate
- Simulation profile
- AI diagnostic context
Site reality
Built for how mines actually run
Remote, dusty, half-connected, and full of hardware that’s been in the ground for a decade. The platform is built around those facts, not around a clean lab.
Intermittent links
Dirty data, kept honest
Hardware you already run
Air-gapped and offline-ready
AI that explains, never controls
Beyond mining
The platform doesn’t know it’s a mine
The engine is vertical-agnostic. The device-type system, the historian, the simulation runtime and the server-driven UI care nothing for the industry — they care about typed equipment. Build the library, and the same platform runs the plant.
Mining is the first library, not the ceiling. As the standard library grows, the reachable verticals grow with it. These are the direction of travel — not shipped libraries. Today the proven ground is mining: a dam pump station and the coal handling beside it.
Start where it matters most.
Bring your pump station, your conveyors and your MCC sections. A 30-minute walkthrough on a live plant model, built from the same typed devices.