xCognition: A Foundational AI Framework for Real-World Data-Driven Cognitive Control in Industrial Robotics and Automation

Max Moruzzi

CEO, Xaba

Abstract:

xCognition is a novel foundational AI platform designed to bridge the gap between physical manufacturing systems and cognitive intelligence. Developed by Xaba, xCognition enables robots, machines, and industrial equipment to autonomously generate executable control logic, including both robotic task programs and PLC code, by learning from real-world data acquired through multi-modal sensing (e.g., 3D vision, force-torque feedback, voltage, RPM, and load cell measurements).

Unlike conventional AI approaches that require large, structured datasets, xCognition integrates physics-based modeling and Bayesian Neural Networks (BNNs) to generate robust synthetic data that supports learning in sparse, dynamic, and non-linear industrial environments. This allows the system to adapt to changing geometries, materials, and environmental conditions with high fidelity and minimal human intervention.

This presentation will explore the platform’s core architecture and scientific principles, including:

• Data-driven trajectory optimization using energy-aware AI models
• Autonomously generated PLC code for legacy and modern industrial controllers
• Real-time adaptation and continuous learning from shop floor data

We will present case studies across robotic welding, precision drilling, grinding, polishing and more to demonstrate how xCognition achieves significant improvements in accuracy, energy efficiency, part quality, deployment time, and overall process robustness and scalability.

This work contributes to the emerging field of cognitive manufacturing systems by demonstrating a scalable approach to embed learning, reasoning, and self-programming capabilities directly into industrial equipment, paving the way for autonomous, intelligent factories.

Biography:

Massimiliano (Max) has an extensive 15+ year career as Lead Scientist and Business Innovator in the fields of Sustainable Materials and Disruptive Manufacturing Process Automation, with a deep experience in the Business-Technology interface and capacity to identify/align emerging technology needs with products and services. He co-founded Augmenta.ai & Xaba.ai with the goal of unlocking the full power of Generative (AI) and Intelligent Automation.

Max is currently the CEO of Xaba (Xaba.ai) a startup focused on developing Foundational AI to capture Real World Data in Industrial Automation, augmenting robots and machines with a Cognitive Synthetic Brain .

Previously, Moruzzi worked for Autodesk as senior scientist through a company acquisition of Magestic Inc. where he was the lead scientist and director of business development with the responsibilities of identifying, developing and structuring strategic partnerships and proposals, and revolutionizing the business models of major OEMs in aerospace (Boeing, Airbus, Lockheed Martin) and automotive (FCA, GM, FORD, Lamborghini, Ferrari).

Max Moruzzi moved to the USA in 2002 to take the role of director of engineering for Ingersoll Machine Tools. During 2002 and 2009, he led a team of scientists and engineers  that developed an innovative machine (advanced fiber placement) and software suite to enable and automate the manufacturing of the fuselage and wings of the Boeing 787 Dreamliner, the first carbon fiber aircraft.

Max Moruzzi is passionate about robotics, cognitive controls, and the science of materials. He has been on the cutting edge of innovation, as well as industrial process automation and digitalization, for years – from next generation aircrafts to smart autonomous cars.

Max Moruzzi holds a master degree in aerospace from the Politecnico of Milan, a masters degree in AI for big data analytics from Northern Illinois University and a third master degree in AI applied to Robotics from the University of Cincinnati.

https://www.engineering.com/story/autodesks-massimiliano-moruzzi-mad-max-or-visionary