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!

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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.

01
Complete 2D scan of extremely large structural components with complex geometries.
02
3D high resolution scans of regions of interest at almost any position in the RoboCT cell.
03
RoboCT features a digital twin, which simplifies setup and monitoring
of CT scans.
04
Autonomous deciding on the appropriate CT scanning method, either 2D laminography or 3D CT scan.
05
Upgradeable with in-house AI analysis software.
06
Stitching of multiple CT scans is easily achievable, resulting in one X-ray image covering the entire scanned object.
07
The versatile RoboCT has lower long-term costs and less personnel training time is required compared to several conventional X-ray systems with less flexibility.
08
Use of standard industrial robots, inexpensive in acquisition, maintenance and repair.
09
RoboCT contributes to the decarbonization of our environment as the flexibility of one RoboCT compensates multiple standard CT 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.

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  • 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
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  • Railway axles
  • Wheel sets
  • Bogie frames
  • Pantograph assemblies
  • Signal equipment
  • Electronics enclosures
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  • 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
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  • 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
1 4 Robo-CT
  • Torpedo or missile storage compartments
  • Missiles or rockets
  • Large caliber gun barrels
  • Composite armor plating segments
  • Entire UAV or large components
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  • Formula one cars
  • Formula H cars
  • Speed boats
  • Air racing aircraft
  • Racing motorcycle
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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.

Picture Reference, implement in Impressum: Von pixabay.com: webandi
Picture Reference, implement in Impressum: Von pexels.com: Jeffry Surianto,
Picture Reference, implement in Impressum: Von pexels.com: Jeffry Surianto,
Von pixabay.com: lamangala
Von pixabay.com: axalant
Von pixabay.com: dayamay
Von pexels.com: SpaceX
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  • 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
Von unsplash.com: Sitraka
Von pexels.com: Mike Bird
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  • 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
Von pixabay.com: pasja1000
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  • Railway axles
  • Wheel sets
  • Bogie frames
  • Pantograph assemblies
  • Signal equipment
  • Electronics enclosures
Von unsplash.com: Rob Pumphrey
Von pixabay.com: hpgruesen
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  • 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
Von freepik.com: godesign3d
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  • 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
1 4 Robo-CT
  • Torpedo or missile storage compartments
  • Missiles or rockets
  • Large caliber gun barrels
  • Composite armor plating segments
  • Entire UAV or large components
Von pixabay: Skitterphoto
Von freeimages.com: kkiser
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  • Formula one cars
  • Formula H cars
  • Speed boats
  • Air racing aircraft
  • Racing motorcycle
Von pixabay.com: Netsyscom
Von unsplash.com: Paul Byrne
Von pixabay.com: you428
Von pixabay.com: alt11
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RoboCT 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.

IMG 20240104 WA0015 1 1 Robo-CT
RoboCT large field-of-view laminography

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.

6 1 scaled Robo-CT

Another example is an 8000 mm long GFRP wing of a Schempp-Hirth Discus sailplane with 101120 × 12160 pixels.

Bild Robo-CT

The red marker indicates the position of a ROI that were examined in more detail using high-resolution CT scans.

ddd scaled Robo-CT
dddddddddd 1 Robo-CT
10 Robo-CT

High-resolution CT scans of the red marked ROI at the wing spar

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