Eaton integrates AI and digital twins in switchgear

Eaton is revolutionising power infrastructure by integrating AI and digital twin technology into switchgear systems, enhancing reliability, scalability, and efficiency for India’s rapidly growing smart cities and data centre ecosystems.

The energy and infrastructure landscape of India is rapidly evolving, driven by smart cities, metro rail projects, industrial corridors and a booming data centre sector. In this dynamic environment, Eaton is at the forefront of empowering the transformation with intelligent, future-ready switchgear and power solutions. By embedding digital intelligence, AI and real-time analytics into its systems, Eaton is enabling predictive maintenance, adaptive performance and enhanced energy management. With deep investments in local manufacturing, R&D, and innovations like the 9395XR UPS and digital twin technology, Eaton is not only addressing India’s current infrastructure demands but also shaping a resilient and sustainable energy ecosystem for the future. Syed Sajjadh Ali, Managing Director, Electrical Sector, India, Eaton shares more insights in talks with EPR.

How is Eaton leveraging digital intelligence in switchgear to address the evolving demands of India’s smart cities and data centres?

India is undergoing a major transformation in urban infrastructure, driven by smart city initiatives, metro expansions and industrial corridor developments. Simultaneously, the data centre market is experiencing significant growth, with capacity expected to reach 2 GW by 2026-27. This surge is fuelled by AI, 5G and cloud adoption. 

At Eaton, we view this as a tremendous opportunity to make a meaningful contribution to India’s infrastructure evolution. Our medium- and low-voltage switchgear solutions are designed to meet the complex demands of modern urban environments and mission-critical facilities, such as data centres. We are integrating digital intelligence into our switchgear systems to enable real-time monitoring, predictive maintenance and enhanced energy management. 

To support this growth, we have strengthened our manufacturing footprint in India with manufacturing expansion in Pondicherry, and we continue to invest in R&D to support ‘Make in India’ products for our customers. Our focus on digitalisation and energy transition aligns perfectly with the needs of these sectors, allowing us to deliver safe, sustainable and high-performance solutions tailored to Indian conditions. 

Over the past decade, we have expanded and diversified across various segments. In electrical distribution, our offerings now include MCCBs, ACBs, contactors, and residual current devices, providing a comprehensive portfolio to meet diverse customer needs. We are also active in the medium voltage segment, which has been a significant success for us. The kind of growth that we have witnessed here is phenomenal. By the end of 2025, we aim to be among the top 5 companies in the medium voltage segment, including RVAC Ring Main Units (RMUs), in the 11 kV switchgear segment. 

Recently, we introduced the 9395XR UPS, a cutting-edge 1.8 MW single-unit system that delivers unmatched performance in an ultra-compact design occupying less than 1.5 square meters. This product exemplifies technological sophistication, offering scalability, modular architecture and best-in-class efficiency, all tailored to meet the evolving demands of mission-critical applications.

How is Eaton using AI and real-time analytics to enable predictive maintenance and adaptive performance in modern switchgear systems?

AI and real-time data analytics are fundamentally transforming how switchgear systems are monitored, maintained and optimised. Traditionally, switchgear maintenance was either reactive or scheduled, often resulting in unexpected failures or inefficient servicing. With AI-driven analytics, we can now predict potential issues before they occur, enabling condition-based and predictive maintenance strategies that optimise asset performance. 

At Eaton, we are integrating intelligent diagnostics and cloud-connected platforms into our switchgear solutions. These systems provide actionable insights through intuitive dashboards, helping facility managers and engineers make informed decisions quickly. The result is reduced downtime, optimised energy usage and improved safety. 

Moreover, AI enables adaptive performance tuning, where switchgear can respond dynamically to changing load conditions or grid demands. This is especially critical in environments such as data centres and smart buildings, where uptime and efficiency are paramount. 

In essence, AI and analytics are shifting switchgear management from a reactive model to a proactive, intelligent ecosystem that delivers long-term value across industrial, commercial, and utility sectors.

How is Eaton enabling future-ready power infrastructure amid India’s switchgear market transformation?

The Indian switchgear market is witnessing robust growth, driven by rapid urbanisation, renewable energy expansion and the push for grid modernisation. At Eaton, we are well-positioned to lead in this evolving landscape. Our focus on smart, reliable and energy-efficient solutions aligns perfectly with the market’s shift toward digitalisation and sustainability. We are investing in local manufacturing to ensure product authenticity and maintain a strong service network. Our goal is to deliver not just products but resilient, future-ready power infrastructure for India’s next phase of growth. Additionally, we identify strong opportunities in EV charging solutions, leveraging our expertise in smart power distribution.

How is your company leveraging digital twin technology to optimise EV infrastructure planning and deployment in diverse and challenging environments?

Digital twin technology creates virtual replicas of EV infrastructure, allowing planners to simulate performance across varied terrains and conditions, urban congestion, rural grid limitations and climate impacts. By integrating real-time data, such as traffic flow, energy demand, and GIS mapping, digital twins help optimise charger placement, predict grid impact, and reduce deployment risks. 

At Eaton, we use this technology to support data-driven decisions and ensure scalable, resilient EV networks that adapt to evolving user and environmental needs across the globe. It also enables faster prototyping and scenario testing, helping stakeholders evaluate multiple deployment models before committing to physical infrastructure. This is especially valuable in regions with limited grid capacity or challenging topography, where precision planning is critical. 

Ultimately, digital twins empower planners to build smarter, more sustainable EV ecosystems that are future-ready and responsive to dynamic mobility patterns.

How is Eaton leveraging the PM E-Drive Scheme to deliver scalable, sustainable and future-ready EV charging infrastructure across India?

Leveraging the PM E-Drive Scheme, Eaton is strategically positioned to support India’s ambitious goal of deploying 72,000 public EV charging stations. Our approach focuses on delivering scalable, intelligent, and sustainable charging infrastructure that aligns with the government’s vision for clean mobility and energy transition. 

Our expertise in smart power distribution and grid integration allows us to design charging networks that are not only reliable but also future-ready. We plan to deploy charging solutions that can be tailored to urban, semi-urban, and rural environments, ensuring accessibility and performance across diverse terrains. 

A key part of our strategy is integrating renewable energy sources, such as solar, with charging systems supported by advanced energy storage and load management technologies. This enhances grid stability and reduces carbon footprint, making the infrastructure more sustainable and cost-effective. 

Additionally, Eaton’s digital platforms will enable real-time monitoring, predictive maintenance, and energy optimisation across the charging network. These capabilities ensure high uptime, user convenience, and operational efficiency, which are critical for scaling to thousands of locations. 

We are actively engaging with government bodies, urban planners and private stakeholders to co-develop deployment models that meet regional needs while supporting national targets. Through local manufacturing, innovation centres, and strategic partnerships, Eaton is committed to accelerating India’s EV infrastructure rollout under the PM E-Drive initiative.

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