Cognigear

Architecting the Future of
Industrial Autonomy.

Specialized consulting for AHS deployment, safety-case engineering, and mixed-fleet interoperability. We help OEMs and operators navigate the shift to Layer 3 vehicle intelligence.

Request Scoping WorkshopExplore the 8 Layers
Autonomous haul truck with digital twin safety overlay in a mining environment

Vertical Focus

Specialized expertise for the most demanding physical-AI environments on the planet.

Surface Mining
Autonomous Haulage Systems (AHS)
Construction
Automated Earthmoving & Grading
Quarry Operations
Graduated Autonomy & Tele-op
Underground Mining
GPS-Denied Navigation & LHD

Specialized Expertise for the Next Decade of Autonomy.

We solve the complex architectural and interoperability challenges that incumbents face when scaling autonomous operations.

Mixed mining fleet with digital interop heartbeats
Interoperability Standards

Implementing ISO 23725 & EMESRT Level 9 for mixed-vendor fleets (CAT, Komatsu, Hitachi).

Edge AI compute unit with 3D safety envelope overlay
Safety-Case Engineering

Navigating the shift from FMS-based safety to Onboard (Layer 3) vehicle intelligence.

Mining pit bird's-eye view with productivity heatmaps
System-Level Optimization

Multi-machine coordination achieving 30%+ productivity gains and 40% tire life improvement.

Unified Interoperability Control.

Real-time monitoring of ISO 23725 heartbeats across a heterogeneous fleet.

SYSTEM STATUS: OPERATIONAL
AOZ: NORTH PIT SECTOR 4
Asset ID
OEM
Status
Latency
ISO 23725
CAT-793F-01
Caterpillar
Active
42ms
CERTIFIED
KOM-930E-04
Komatsu
Active
38ms
CERTIFIED
HIT-EX8000-02
Hitachi
Active
55ms
CERTIFIED
CAT-793F-02
Caterpillar
Standby
40ms
CERTIFIED

Protocol Health

V2V Coordination99.9%
Safety Envelope Sync100%

Action Required

New Hitachi Excavator detected in Sector 4. Initialize ISO 23725 handshake.

HAUL TRUCK
Layer 3 Safety Envelope
OBSTACLE
Decision Engine
Local Compute: Evasive Action Initiated

Edge Safety Simulation.

When the network fails, the vehicle shouldn't. We specialize in transitioning the safety case from the central fleet system to on-vehicle edge compute.

Layer 2: FMS-Dependent Safety

Vehicle relies on continuous network connection. Disconnection = Emergency Stop.

Layer 3: Onboard Edge Intelligence

Vehicle maintains local world model and safety envelope. Operates safely during network brownouts.

The Autonomy Business Case.

Autonomy isn't just about safety—it's about the bottom line. Use our calculator to see the potential EBITDA impact of an AHS conversion.

20 Trucks
Estimated Annual Impact
Productivity Uplift (30%)
+$6.0M EBITDA / yr
Maintenance & Tire Savings (40%)
+$1.0M OPEX / yr
Total Value Unlocked
$7.0M
Core Capabilities

Autonomy expertise. Operational reality.

Autonomous site survey
Site Autonomy Readiness

Is your site ready for robots?

Identify 3–7 safe, high-ROI autonomy use cases for your industrial site in 3 weeks.

What's included:

  • ✓Network & connectivity audit
  • ✓Operational process mapping
  • ✓Safety barrier analysis
  • ✓ROI projections & business case
  • ✓Deployment risk assessment
Bespoke Engagement
Strategic Workshop
Strategic planning session
Autonomy Make–Buy–Partner Strategy

Don't build commodity tech

Decide which parts of the autonomy stack to build, license, or partner for (perception, planning, control, teleop).

What's included:

  • ✓Stack decomposition
  • ✓Market scan of solutions
  • ✓Build vs Buy financial modeling
  • ✓IP ownership strategy
  • ✓Partner vetting
Bespoke Engagement
Advisory Sprint
Data analytics dashboard
Fleet Metrics & Evaluation

Trust but verify

Define the 'Golden Metrics' that matter for safety and ROI. Turn terabytes of vehicle logs into a clear health score.

What's included:

  • ✓KPI definition workshop
  • ✓Log analysis pipeline design
  • ✓Safety intervention metrics
  • ✓Utilization efficiency tracking
  • ✓Operations Control Center dashboard
Bespoke Engagement
Continuous Partnership

Specialized Engineering Services

Deep-dive technical services to unblock your specific autonomy challenges.

image of team discussion (for a hr tech)

Simulation & Validation

Design scenario libraries and HIL/SIL benches to validate behavior before deployment.

image of investment portfolio

Teleoperations Design

Architect low-latency supervisor loops human-in-the-loop fallback systems.

image of a team brainstorming in an office (for a web development agency) [background image]

Functional Safety Audit

Align stack architecture with ISO 26262/SOTIF standards for industrial environments.

The Future of Your Fleet is Autonomous.

From Layer 3 safety-case engineering to site-wide interoperability, we provide the technical depth required to scale beyond the pilot phase.

Request Scoping CallExplore the 8 Layers

Frequently asked questions

Get answers to common questions about our enterprise AI consulting services

Autonomy Insights Delivered

Expert insights and best practices for enterprise AI transformation

Assessment

AI Readiness Assessment: A Complete Guide

Learn how to evaluate your organization's AI readiness across technology, data, processes, and people.

8 min readRead more →
Strategy

Enterprise AI Strategy: Building Your Roadmap

Discover the key components of a successful AI strategy and how to create an implementation roadmap.

12 min readRead more →
Implementation

AI Implementation: Common Pitfalls to Avoid

Avoid costly mistakes with our guide to successful AI implementation in enterprise environments.

10 min readRead more →
View all insights

Ready to get started?

Contact us to discuss your AI transformation needs. We'll provide a personalized consultation to help you achieve your goals.

Email

consulting@cognigear.com

Phone

+1 (210) 413-4247

Office

McLean, VA