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Governed Capability Evolution: Lifecycle-Time Compatibility Checking and Rollback for AI-Component-Based Systems, with Embodied Agents as Case Study

Software systems built from versioned AI components increasingly need lifecycle-time governance: when a capability module evolves into a new version, the hosting system must decide whether the new version may be activated safely, under what deployment conditions it should run, how it must be monitored, and when it should be rolled back. Existing software-deployment patterns (canary release, blue-green, feature flags, and MLOps pipelines) address parts of this loop but were designed for stateless web services rather than for stateful, policy-constrained runtimes that drive AI components in the field. We formulate governed capability evolution as a first-class software-lifecycle problem for AI-component-based systems and propose a staged upgrade framework in which every new capability version is treated as a governed deployment candidate rather than an immediately executable replacement. The framework introduces four upgrade compatibility checks (interface, policy, behavioral, recovery) and organizes them into a seven-stage pipeline (candidate validation, sandbox evaluation, shadow deployment, gated activation, online monitoring, rollback, audit). We implement a reference prototype on a PyBullet manipulation testbed with ROS 2 middleware and evaluate it over 6 rounds of capability upgrade with 15 random seeds. Naive upgrade achieves 72.9% task success but drives unsafe activation to 60% by the final round; governed upgrade retains comparable success (67.4%) while maintaining zero unsafe activations across all rounds (Wilcoxon p=0.003). Shadow deployment reveals 40% of upgrade regressions invisible to sandbox evaluation alone, and rollback succeeds in 79.8% of post-activation drift scenarios.

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