Replica Twin · Replica Lab
Replica connects real equipment to physics-based digital twins that catch wear before it becomes downtime, and turns the same models into hands-on virtual labs for students.
Two products, one physics engine
Replica Twin
Sensors stream in. A physics model predicts what the machine should be doing. The gap between the two is the earliest sign of wear, and the twin turns it into a plain-language maintenance forecast.
Replica Lab
Students operate a simulation of the equipment in their own lab, on any phone. An AI tutor explains what is happening in Hindi or English, and every session counts toward practical-hour reports.
How a live twin works
An ESP32, Raspberry Pi or PLC bridge posts speed, flow, head and temperature over HTTPS. No new SCADA needed.
For the exact live conditions, the twin computes what this machine should deliver: flow, head, power, NPSH.
A growing gap between measured and predicted is the earliest sign of impeller wear, fouling or a failing bearing. The trend becomes a time-to-alarm forecast.
Engineers send setpoints back to the machine, and the gateway confirms them. Incidents and commands are logged for audit.
Replica Lab
Students change speed, valve and temperature on a model of their department's own rig, then ask why. The tutor answers from the live readings, not from a generic textbook.
Where it fits
Universities, polytechnics and ITIs. Virtual labs for every student, plus a live twin of the real rig in the lab for remote practice.
Steel, power, cement and water. Predictive maintenance for pumps, motors and fans, starting with a single critical machine.
Polyhouses and protected cultivation. Climate twins that tell growers in Hindi when to vent, shade or switch on the pad.
Platform
Every institution's data is isolated. Roles for owners, admins, faculty and students, with join codes, invitations, bulk import and a full audit log.
Runs in any browser, on any phone.
Models are data, not code. Faculty-written formulas are parsed and sandboxed, with no eval.
head = H0·s² − A·Q²
Each machine gets its own revocable key. Only a hash is stored.
Hysteresis and persistence rules, the same practice used in industrial alarm management, so engineers trust every alert they get.
FAQ
Replica, by Vachak AI, is a web platform with two products on one physics engine. Replica Twin gives real equipment a live digital twin for predictive maintenance. Replica Lab gives students simulation-based virtual labs of specific equipment, with an AI tutor and practical-hours reports. It runs in any browser, including on budget Android phones.
A simulation is a model you drive by hand. A digital twin is a model of one specific real machine, kept in sync automatically by that machine's sensors, and able to send commands back to it. Replica Lab is a simulation. Replica Twin is a digital twin: sensors stream in, and engineers can send setpoints back.
For the machine's exact live conditions, the physics model computes what it should be delivering, such as flow, head and power. Replica compares that with what the sensors measure. A growing gap is the earliest sign of wear such as impeller wear, fouling or a failing bearing, and Replica turns the trend into a time-to-alarm forecast. Because it is physics-based, it works from day one on a single machine without years of failure history.
Sensors on the machine and a small gateway, such as an ESP32, a Raspberry Pi or a PLC bridge, that posts readings to Replica over HTTPS. No new SCADA system is needed. Each machine gets its own revocable device key.
No. Replica Lab runs in the web browser on any phone or computer. There is nothing to install.
Hindi and English. Students can type or, where the browser supports it, ask by voice. The tutor answers from the simulation's live readings, not from a generic textbook.
Yes. Faculty describe a machine and AI drafts a model with formulas, alerts and syllabus notes. A subject expert reviews it before publishing. Models can also be written or edited directly in the Model builder.
Yes. Every organisation's data is isolated. Access is controlled by roles (owner, admin, faculty and student), and changes are recorded in an audit log.
Create your organisation online in about a minute. You can try a live twin with the built-in pump simulator before any hardware arrives, and invite students with a join code.
Create your organisation in a minute. Use the built-in pump simulator before any hardware arrives.