RoundProof — Autonomous Robotic & Drone Inspection Intelligence

Overview

RoundProof is an enterprise inspection intelligence and maintenance automation platform for continuous energy and industrial production facilities. Operating as a hardware-agnostic operational layer between robotic fleets (ANYmal, Boston Dynamics Spot, drones) and enterprise plant maintenance workflows, RoundProof transforms multi-modal sensor streams into verified maintenance notifications in SAP PM and IBM Maximo with zero manual data re-entry.

The Problem

Process facilities rely on scheduled inspection rounds to detect mechanical wear, thermal hotspots, and leaks. Deploying autonomous robotic fleets produces massive volumes of uncontextualized sensor data:

• Telemetry is detached from the facility digital twin, functional location hierarchy (FLOC), and P&ID drawings.
• Generic AI models generate noisy alerts, overwhelming reliability teams with alarm fatigue.
• Maintenance work orders still require tedious, manual data re-entry into legacy CMMS systems.
• Audits, insurers, and regulators lack a verifiable chain of custody for robotic inspection data.

The Solution

RoundProof closes the loop from autonomous inspection to enterprise work order dispatch. It normalizes multi-sensor payloads into the Plant Coordinate System (PCS), matches observations against engineering asset baselines, applies deterministic standards-based classifiers, enforces human-in-the-loop (HITL) engineering validation, and dispatches approved findings into SAP PM or IBM Maximo with complete cryptographic provenance.

Key Capabilities

• Hardware-Agnostic Fleet Abstraction: Extended VDA 5050 messaging and SE(3) spatial normalization calibrate heterogeneous robots into the Plant Coordinate System.
• Functional Location (FLOC) Resolution: Automatically maps inspection observations to equipment tags, component hierarchies, and P&ID drawings without manual tagging.
• Deterministic Standards-Aware Analytics:
  • Radiometric Thermal (LWIR): NETA MTS severity tiering with phase-to-phase and component-to-ambient differential calculations.
  • Ultrasonic Thickness (UT): API 581 corrosion rate modeling, wall thickness calculation, and remaining service life forecasting.
  • Acoustic Leak Detection: Acoustic beamforming with mandatory thermal cross-validation to eliminate acoustic reflections.
  • Optical OCR & State Verification: Out-of-range gauge needle reading and valve stem status verification.
  • Gas Plume Alerts (OGI/TDLAS): Hydrocarbon and toxic gas detection routed directly to HSE and reliability teams.
• Human-in-the-Loop (HITL) Governance: Prioritized engineering inbox where certified engineers review, modulate, or reject findings with standardized reason codes. No unvalidated defect reaches the plant CMMS.
• Automated Enterprise CMMS Dispatch: Resilient transactional outbox connecting directly with SAP PM (REST/BAPI) and IBM Maximo (OSLC).
• Tamper-Evident Audit Ledger: Append-only SHA-256 hash-chained ledger sealing robot pose, calibration, analysis version, reviewer identity, and dispatch timestamps into compliance packs.

Business Benefits

• Zero Manual Data Re-entry: Eliminate manual transcribing of inspection round logs into enterprise maintenance software.
• Eliminate Unvalidated AI Dispatches: Guarantee 100% human engineering accountability before maintenance tickets are created.
• Extend Asset Uptime: Early detection of mechanical wear, bearing failures, and wall thinning prevents unplanned shutdowns.
• Audit & Insurer Proof: Export cryptographically verifiable inspection records to satisfy safety regulators and underwriters.

How It Works

1. Plan & Dispatch: Constrained routes are calculated respecting battery limits and ATEX/IECEx hazard zones.
2. Ingest & Normalize: Observations from thermal, optical, acoustic, and UT sensors are mapped into the plant digital twin.
3. Analyze: Standards-based analytics compute degradation trends and flag candidate anomalies.
4. HITL Review: Reliability engineers inspect evidence side-by-side with baselines and approve/reject with reason codes.
5. CMMS Dispatch: Approved findings instantly generate work orders in SAP PM or Maximo with full audit provenance.