# Replica

> Replica, by Vachak AI (Chhattisgarh, India), is a web platform with two products on one physics engine: Replica Twin, live digital twins of real equipment for predictive maintenance, and Replica Lab, simulation-based virtual labs of specific equipment for universities, polytechnics and ITIs. It runs in any browser, including budget Android phones, and needs no headset.

## Replica Twin: live digital twins

A live digital twin is a physics model of one real machine, kept in sync by that machine's sensors. Replica compares what the machine measures with what the physics model says it should do under the same live conditions. A growing gap between the two is the earliest sign of wear such as impeller wear, fouling or a failing bearing.

- Health score per machine (100 means it behaves exactly as the model predicts).
- Model-vs-measured deviation per sensor, with warning and alarm limits that use hysteresis and persistence, so alarms do not flood.
- Physics alerts from live conditions, for example pump cavitation when available NPSH falls below required NPSH.
- Degradation trend and time-to-alarm forecast in plain language.
- Two-way control: engineers send setpoints to the machine and the gateway confirms them; incidents and commands are logged.
- Sensors connect over HTTPS from an ESP32, Raspberry Pi or PLC bridge; no new SCADA system is needed.
- Because it is physics-based, it works from day one on a single machine and does not need years of failure history.

## Replica Lab: virtual labs

Replica Lab is a simulation (a digital model), not a digital twin: students set the inputs themselves.

- Students operate a simulation of the specific equipment in their department's lab, on any phone.
- An AI tutor answers questions in Hindi or English, by text or voice, using the live simulated readings.
- Faculty can describe a machine and have AI draft a model (formulas, alerts, syllabus notes) for an expert to review before publishing.
- Active practice time per student and equipment is recorded, with idle gaps excluded, and exported as CSV practical-hours reports.
- Library models include a centrifugal pump, a DC shunt motor, a polyhouse, a solar pump for drip irrigation and an induced draft fan with a variable frequency drive.

## Who it is for

- Industry: steel, power, cement and water utilities; predictive maintenance for pumps, motors and fans, starting with one critical machine.
- Education: universities, polytechnics and ITIs; virtual labs for every student and a live twin of a real lab rig for remote practice.
- Agriculture: polyhouses and FPOs; climate monitoring with Hindi advice.

## Platform

- Multi-tenant SaaS: each organisation's data is isolated; roles for owners, admins, faculty and students; join codes, invitations, bulk import and an audit log.
- Formulas are data, parsed by a sandboxed expression engine (no eval).
- Each machine has its own revocable device key; only a hash is stored.

## Links

- [Website](https://replicaai.in/): product overview, how a live twin works, industries and FAQ
- [Create an organisation](https://replicaai.in/app#/signup): free sign-up
- [Sign in](https://replicaai.in/app#/login)