The manual answers. Even at 3am.
PLC programs, SCADA, wiring diagrams and machine manuals become one thing you can ask in plain words — inside the factory network, no cloud, nothing leaving the site.
Ask about an alarm the way you'd ask a colleague.
The Box reads Rockwell Studio 5000 projects and Ignition exports: for any alarm it tells you what raises it, where in the program, and what to do to clear it.
Alarm diagnosis
Ask "alarm 4.16" and get cause, reset conditions and consequences, with the rung interpreted and a flowchart.
Tag cross-reference
Who writes and who reads a tag: the complete usage map to understand dependencies before touching the logic.
Ignition HMI texts
Find the alarm starting from the phrase the operator reads at the machine: Ignition texts are indexed and linked to bits.
Explore the project
Overview of programs and routines, search across project files and ladder logic reading with an instruction glossary.
One vertical use case: production and plants. When real-time factory data matters.
For manufacturing companies, IntelligenceBox can bring generative AI close to lines, sensors, alarms and machine history. It is a vertical extension of the platform, not its only field of application.
Production dashboard
Tags, history and alarms processed locally
94%
Stable OEE
81%
Vibration threshold
68%
Thermal anomaly
Process signals
AI priorities
Check Line C motor bearing before the next shift.
Correlate scrap on batch 428 with the 09:40 recipe change.
Reduce oven 2 setpoint to return inside the energy profile.
Predictive maintenance
Reads history, thresholds and machine patterns to anticipate stoppages and suggest interventions.
Quality control
Connects batches, parameters and non-conformities to explain deviations and likely causes.
Clear alarms
Summarizes alarm chains, priorities and operational context in natural language.
Operational decisions
Turns line data into actions for shifts, energy, scrap and throughput.
Ignition integration. From gateway to local AI.
The app connects Ignition 8.3+ without code in Designer: it installs a dedicated Web Dev project, uses a runtime key and makes tags, history, alarms and queries available to the assistant.
Admin token
Paste gateway URL and API token only to install the project.
ai_api project
The Box uploads a Web Dev resource on POST /api with a Python dispatcher.
Runtime key
Operational calls use a dedicated key, not the admin token.
Supported operations
Ignition data ready for chat, reports and widgets
Built for OT environments.
The integration separates setup and runtime, reduces persistent credentials and keeps the gateway inside the industrial network.
The admin token is used only for project import and is not stored.
The ai_api project can be replaced with controlled overwrite.
Runtime operations expose only the functions the assistant needs.
Ignition sees. IntelligenceBox understands.
Two layers that complement each other: Ignition captures and controls field data, IntelligenceBox interprets it and produces decisions.
Ignition
The layer that captures and controls
- Captures tags from PLCs and sensors in real time
- Historises everything in the Tag Historian
- Generates and notifies alarms (email, SMS, voice)
- Displays HMIs, dashboards and reporting
IntelligenceBox
The layer that interprets and produces
- Answers questions in natural language
- Correlates data with internal manuals and documents
- Generates ready-to-send reports, PPTX and Excel
- Forecasts and flags deviations from targets
The result: Ignition's data becomes decisions — in seconds, on the line, without leaving the network.
From a question to a decision, right on the line.
Five real scenarios on top of your existing Ignition projects — same field data, a new natural-language interface.
Run time & alarms
How is Line 2 doing today? Are there any open alarms?
What IntelligenceBox does
- Reads Ignition's Tag Historian and alarm journal
- Computes run time, stoppages and shift availability
- Lists active alarms with priority and duration
- Answers right away, by voice or chat, on the line
Line 2 — morning shift: run time 94%, 3 micro-stops (28 min total). 1 active alarm: spindle over-temperature (6 min).
Energy consumption
Prepare April's consumption presentation for the energy manager.
What IntelligenceBox does
- Generates a consumption PPTX, ready to send
- Produces consumption certificates for reporting and audits
- Suggests energy-management scheduling (loads and time bands)
April_Consumption_2026.pptx — generated in 12 s
Maintenance
'Overcurrent' alarm on belt 3: what's the correct procedure?
What IntelligenceBox does
- Acquires the alarm from the journal with code, asset and timestamp
- Links the motor manual, the asset's history and the spare-parts sheet
- Suggests the procedure: isolate, check the mechanical load, verify the thermal setting
The right procedure reaches the operator the moment the alarm fires.
Forecasts
At today's pace, will I close the week within the production target?
What IntelligenceBox does
- Compares actual production with the weekly target
- Projects the close at the current pace and flags the gap
- Cross-references consumption and production in an EMS model
- Exports a ready EMS Excel for management control
92% of the expected pace — estimated close: Fri 17:40, ~3% below target.
Documents
What's the bolt tightening torque for the DN80 flange?
What IntelligenceBox does
- Semantic search across every document, scans included (OCR)
- Concise answers with a reference to the document and page
- Index and contents stay local: no external uploads
For the DN80 PN16 flange the torque is 95 N·m, in 3 cross passes, M16 8.8 bolts. Source: flange_manual.pdf · p.42
What changes on the plant floor.
From fragmented data to answers, reports and decisions — without anything leaving your network.
Reports in minutes
Consumption, downtime and KPIs generated on demand. Hours of copy-paste become seconds.
Decisions on the line
Line status and forecasts one question away, without opening a dashboard.
Less downtime
Alarms correlated with manuals and history: the right procedure reaches the operator immediately.
Energy efficiency
Consumption always under control and load scheduling to cut the bill.
Data kept safe
Everything stays on the factory network: nothing to justify in an audit, no usage-based costs.
Ready from day one
It connects to the Ignition you already run. Nothing on the plant gets touched.
Bring it into your plant.
A demo on your own setup: bring us a PLC project or a wiring diagram and watch the answers live.