Introducing the RoboCT Advantage:
Revolutionizing X-Ray Inspection for
Oversized Objects!
At the forefront of innovation, X-RAYLAB’s RoboCT solution addresses the common challenge of oversized objects that simply do not fit into traditional X-ray machines. We understand the need for flexibility in today’s dynamic industries, where large-scale components demand extensive inspection.
About RoboCT
RoboCT is a form of industrial computed tomography (ICT) in which at least one pair of industrial robots is used to move at minimum one X-ray source and one detector around the object. X-RAYLAB, in collaboration with the Fraunhofer EZRT X-Ray Center, has developed RoboCT, which can be used to scan the chosen object in both 2D and 3D through special acquisition trajectories. A typical procedure is a complete 2D scan of the object and a high-resolution CT scan in regions of interest, whereby the X-ray system can decide for itself which CT procedure is most suitable based on the digital twin of the project. The digital twin allows for straightforward configuration and monitoring of complex CT scans.
RoboCT is usually set up with standard industrial robots with a reach of 3 m on the linear axes in a protective enclosure with the dimensions of for example 10 m × 8 m × 4 m (L/W/H). This setup allows objects with a height and width of up to 4 m and an almost unlimited length to be scanned, only restricted by the length of the enclosure. Optional extensions can include a turntable, additional X-ray units or other complementary equipment. We are looking forward to adapting RoboCT to your requirements!
Why RoboCT?
RoboCT has arrived at the TRL 9 level of a ready product and is already being applied in industry from renowned car manufacturers
RoboCT systems have several advantages over conventional industrial Computed Tomography systems.
Possible Applications
RoboCT systems are a valuable tool for a wide range of industries. They can be used to scan large and complex objects quickly and flexibly. This makes them ideal for quality control, product development and process optimization at an economical price.
- Small Helicopters
- Entire empennage
- Fuselage sections
- Large wing sections or complete smaller wings
- Large fuel tanks
- Helicopter blades and rotor assemblies
- Large avionics and instrumentation panels
- Landing gear assemblies
- Cargo bay doors or large access panels
- Spacecraft components
- Complete satellite assemblies
- Complete equipped or unequipped battery boxes
- Megacastings
- Entire car chassis
- Sections of trucks or buses engine areas
- Suspension systems for heavy-duty vehicles
- Transmission systems
- Passenger compartments
- Dashboard assemblies
- Railway axles
- Wheel sets
- Bogie frames
- Pantograph assemblies
- Signal equipment
- Electronics enclosures
- Wind Turbine Components
- Wind turbine rotor blades
- Large solar panel assemblies
- Large electrical transformers and insulators
- Boiler sections for thermal power plants
- Heat exchangers and large cooling pipes
- Pre-cast concrete panels
- Segments for bridges or buildings
- Cranes and bulldozers machinery components
- Elevator shaft components and safety mechanisms
- Reinforcement bar assemblies inside concrete structures
- Prefabricated modular units for buildings
- Plywood structures
- Torpedo or missile storage compartments
- Missiles or rockets
- Large caliber gun barrels
- Composite armor plating segments
- Entire UAV or large components
- Formula one cars
- Formula H cars
- Speed boats
- Air racing aircraft
- Racing motorcycle
Possible Applications
RoboCT systems are a valuable tool for a wide range of industries. They can be used to scan large and complex objects quickly and flexibly. This makes them ideal for quality control, product development and process optimization at an economical price.
- Small Helicopters
- Entire empennage
- Fuselage sections
- Large wing sections or complete smaller wings
- Large fuel tanks
- Helicopter blades and rotor assemblies
- Large avionics and instrumentation panels
- Landing gear assemblies
- Cargo bay doors or large access panels
- Spacecraft components
- Complete satellite assemblies
- Complete equipped or unequipped battery boxes
- Megacastings
- Entire car chassis
- Sections of trucks or buses engine areas
- Suspension systems for heavy-duty vehicles
- Transmission systems
- Passenger compartments
- Dashboard assemblies
- Submarine hull sections
- Large Seals
- Canoes
- Kayaks
- Houseboats
- Motorboats
- Lifeboats
- Mast assemblies
- Propulsion systems
- Rudder assemblies and steering gear
- Fuel tanks and storage containers
- Docking and loading mechanisms
- Railway axles
- Wheel sets
- Bogie frames
- Pantograph assemblies
- Signal equipment
- Electronics enclosures
- Wind Turbine Components
- Wind turbine rotor blades
- Large solar panel assemblies
- Large electrical transformers and insulators
- Boiler sections for thermal power plants
- Heat exchangers and large cooling pipes
- Pre-cast concrete panels
- Segments for bridges or buildings
- Cranes and bulldozers machinery components
- Elevator shaft components and safety mechanisms
- Reinforcement bar assemblies inside concrete structures
- Prefabricated modular units for buildings
- Plywood structures
- Torpedo or missile storage compartments
- Missiles or rockets
- Large caliber gun barrels
- Composite armor plating segments
- Entire UAV or large components
- Formula one cars
- Formula H cars
- Speed boats
- Air racing aircraft
- Racing motorcycle
Robo-CT Technology
Following, we demonstrate different RoboCT 2D acquisition trajectories and their application to a whole CFRP flap with segment dimensions of 800 mm × 160 mm × 1200 mm, while the total length of the CFRP flap equals 7000 mm.
Large Field-of-View Laminography
Large field-of-view laminography is achievable by parallel translational sampling of the object. The 3D information from slightly different perspectives of neighboring projection images is equivalent to laminography with an angle of 17°, which translates to approximately 10 % information of a full 3D CT scan.
Coplanar Circular 2D Laminography
Once it is no longer possible to rotate around the object, an alternative to vertical circular 3D CT is coplanar circular 2D laminography. The data is acquired in three circles angled by 10°, 20° and 30°, each consisting of 128 projections.
RoboCT coplanar circular 2D laminography at the upright flap segment
High-Resolution 3D Scan
Next, we demonstrate different RoboCT 3D acquisition trajectories and their application to a specific region of interest of the CFRP flap. These local 3D scans feature high resolution and help to analyze critical areas.
Vertical Circular 3D CT
Vertical Circular 3D CT serves as a method for high-resolution scans. When full CT scans with > 180° angular range are possible, the results hardly differ from laboratory Micro-CT.
The limited CT angle is 200° with overall 1001 projections and the scan resolution amounted to 50 µm.
RoboCT vertical circular 3D CT at the upright flap segment
Stitching of Radioscopies
The X-RAYLAB RoboCT technology allows to acquire stitched radioscopies of objects at a detail level of 50 µm and below. For instance, a 7000 mm long CFRP fuselage of a DG-800 sailplane with 91261 × 20832 pixels is displayed below.
Another example is an 8000 mm long GFRP wing of a Schempp-Hirth Discus sailplane with 101120 × 12160 pixels.
The red marker indicates the position of a ROI that were examined in more detail using high-resolution CT scans.
High-resolution CT scans of the red marked ROI at the wing spar
