Advanced Manufacturing Solutions

Powered by DeepCtrls’ proprietary PhyAI™ Physical AI Engine, DeepOS serves energy-intensive AI data centers, digital factories and smart campuses. It integrates computing, power, cooling, storage and loads, builds a full electromechanical model and computing-energy coordination hub, and delivers unified source-grid-load-storage dispatch, system-wide optimization and AI predictive O&M.

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Industry Challenges

Advanced Manufacturing’s Energy Challenges

Advanced manufacturing utilities operate under high energy use, complex coupling, and tight constraints,making conventional control unable to sustain optimal efficiency.

High Utility Energy Consumption

Cleanroom HVAC, chilled water, compressed air, and process cooling are major energy consumers with significant potential for system-level optimization.

Strict Process Requirements

Critical manufacturing environments require strict control of temperature, humidity, cleanliness, pressure, air supply, and process cooling—so energy optimization must stay within safety limits.

Complex System Interactions

Tightly coupled equipment and production loads make single-device optimization prone to local optima, limiting plant-wide energy efficiency.

Unsustainable Manual Tuning

Fixed rules and manual tuning struggle to adapt to changing loads, seasons, and equipment performance, making sustained energy savings difficult.

Solutions

Five Facility Energy Solutions for Advanced Manufacturing

Integrated energy optimization for HVAC,compressed air, process cooling, and facility systems in advanced manufacturing.

HVAC Deep Energy Savings

Cut HVAC energy use, stabilize process environments

Optimizes cooling sources, distribution, and terminal systems to reduce energy use while maintaining temperature, humidity, cleanliness, and pressure requirements.

Compressed Air Deep Energy Savings

On‑demand air supply, reduced energy waste

Matches compressed air supply with demand across generation, distribution, and end use to reduce idling, venting, and pressure losses.

Process Cooling & Chiller Plant Optimization

Dynamic Load Matching for Efficient, Stable Cooling

Matches cooling supply with process loads through coordinated chiller, pump, tower, and terminal optimization.

AI-Enabled Facility Energy & FMCS Integration

Unified Facility Management for Energy & O&M Efficiency

Unifies facility systems for monitoring, alerts, energy analytics, smart work orders, and predictive maintenance.

AI Smart O&M

Early risk detection, predictive maintenance

Powered by PhyAI models and real-time data, it detects anomalies, degradation and device health. With diagnosis, root-cause analysis and trend prediction, it shifts from reactive repairs to proactive maintenance.

PhyAI Core Capabilities for Advanced Manufacturing

Efficiency · Control · O&M · Energy Coordination

Powered by PhyAI™, DeepCtrls combines system optimization, AI FMCS, intelligent O&M,and energy coordination to improve efficiency, stability, and operations in advanced manufacturing.

DeepSYS Optimization Agent

10%–40% energy savingsRRMSE<3%Million-scenario optimization

Physics-based modeling and global optimization enable closed-loop control across HVAC, compressed air, chilled water, and process utilities.

AI FMCS

Energy SensingEquipment MonitoringSystem Optimization

DeepOS unifies plant energy and MEP systems with BIM, IoT, and PhyAI for real-time sensing and coordinated optimization.

AI Smart O&M

Health MonitoringRoot Cause AnalysisPredictive Maintenance

Physics-based modeling and AI diagnostics enable health assessment, root-cause analysis, and predictive maintenance.

DeepOS — AI-Native Energy OS

Real-Time Energy SensingSmart Energy SchedulingGlobal Cost Optimization

DeepOS coordinates power, grid, storage, and flexible loads to enable peak shaving, renewable integration, and cost optimization.

Key Benefits

More Efficient. More Stable. More Autonomous.

Powered by PhyAI™, DeepCtrls optimizes HVAC, compressed air, process cooling,and facility systems to cut energy costs while maintaining safe, stable production.

10%–40%

System-Level Energy Optimization

Powered by PhyAI™, DeepCtrls optimizes HVAC, compressed air, cooling plants, and process utilities for minimum system energy use.

10%–40% system energy savingGlobal optimizationSystem-level optimization

Safety Constraints

Stable Production, Reliable Processes

Optimizes energy use within strict limits for temperature, humidity, cleanliness, pressure, air supply, and process cooling to maintain stable production conditions.

Safety-Constrained ControlExplainable & ValidatedStable Operations

AI Closed-Loop Control

Self-Optimizing. Continuously Evolving

Builds a closed loop of sensing, modeling, optimization, control, and validation to adapt to changing loads, seasons, and equipment performance with less manual tuning.

RRMSE＜3%Millions of Scenario SimulationsL4 Closed-Loop Control

10 Minutes

Verifiable Results, Measurable Value

Enables comparison between standard and AI-optimized modes, visualizing energy performance and savings in real time for clear ROI and operational value.

10-Min ValidationVisualized ResultsTraceable Value