Introduction
Inspecting oversized industrial components has long been a challenge. Traditional computed tomography (CT) systems are limited in size, unable to accommodate very large parts or complex geometries efficiently.
RoboCT, developed by XRAY-LAB GmbH & Co. KG, overcomes these challenges by combining robotic precision with advanced X-ray technology. The system allows high-resolution 2D and 3D scans of even the largest industrial parts, making it an ideal solution for aerospace, automotive, energy, and other industries that rely on non-destructive testing.
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RoboCT performing a high-resolution X-ray inspection of an automotive chassis, capturing internal details with robotic precision.
What Is RoboCT?
RoboCT is an inline and at-line industrial computed tomography system specifically designed for oversized and complex objects. Unlike conventional CT machines, RoboCT does not rely on moving the object to be inspected. Instead, the X-ray source and detector are mounted on industrial robots, which move around the object with high precision. This design enables the inspection of components that would otherwise be too large or irregularly shaped for standard CT systems. By leveraging robotic movement, RoboCT provides a flexible, efficient, and highly accurate scanning solution that reduces the need for multiple conventional machines and minimizes manual setup.
The system is capable of performing full 2D scans of large structures, followed by targeted high-resolution 3D scans for regions of interest. Using a digital twin of the object, RoboCT can plan scanning trajectories, monitor the process in real time, and automatically select the most suitable scanning method, whether laminography or full 3D CT. This automation ensures high throughput, minimal human error, and reduced operational costs, all while maintaining the precision required for industrial applications.
How RoboCT Works
The core innovation of RoboCT lies in its robotic X-ray source and detector movement. Instead of being confined to a fixed gantry, the system’s robots navigate around the object, capturing images from multiple angles. This approach allows inspection of parts with large height, width, and length, which traditional CT systems cannot accommodate efficiently. For extremely long components, RoboCT can stitch together multiple images to create a seamless large-field-of-view representation.
Depending on the object’s size and complexity, RoboCT selects between different scanning strategies. Large field-of-view laminography is used for oversized objects, capturing 3D information through translational sampling. When rotation around the object is limited, the system performs angled circular trajectories, creating high-quality images from multiple projections. For areas where full rotational scanning is possible, vertical circular 3D CT provides extremely detailed imaging comparable to micro-CT systems.
The integration of a digital twin allows precise planning of scanning trajectories and monitoring of the inspection process. This digital model ensures that the scanning path is optimized, reducing errors and minimizing manual adjustments. By combining robotic movement, advanced scanning trajectories, and digital twin technology, RoboCT delivers unprecedented flexibility and accuracy for industrial CT inspection.
Applications Across Industries
RoboCT is particularly suited to industries where large, complex components are common. In aerospace, it can inspect fuselage sections, wing assemblies, and satellite structures. In automotive manufacturing, the system can handle entire chassis, battery boxes, and heavy-duty engine components. The energy and construction sectors benefit from RoboCT when scanning wind turbine blades, transformer assemblies, or precast concrete panels. Rail and transportation industries can inspect wheel sets, bogie frames, and large electronics enclosures, while naval and defense applications include submarine hull sections and missile storage compartments.
By enabling high-resolution inspection of large and complex parts, RoboCT ensures that critical defects are detected early, improving quality control and supporting compliance with industry safety standards.
Watch RoboCT in Action: See how RoboCT performs a full-scale X-ray inspection of a car chassis with unmatched precision and speed.
The Value of RoboCT
RoboCT provides unmatched flexibility by eliminating size constraints inherent in traditional CT systems. Manufacturers can inspect oversized and irregularly shaped parts without compromising on resolution or accuracy. The system allows initial 2D scans to identify areas of interest, followed by high-resolution 3D imaging of critical regions. This targeted approach saves time, reduces operational costs, and enhances decision-making.
Furthermore, RoboCT uses standard industrial robots, making it cost-effective to purchase and maintain. A single RoboCT system can replace several conventional CT machines, reducing both capital expenditure and energy consumption. By decreasing the number of machines required for inspection, RoboCT also contributes to sustainability initiatives and lowers the environmental footprint of industrial operations.
When to Consider RoboCT
Manufacturers should consider RoboCT when their parts exceed the size limits of conventional CT systems or when high-resolution 3D scans of specific regions are needed. The system is ideal for inline or at-line inspection processes and integrates seamlessly with digital twin technology to optimize scanning and reduce manual errors. Organizations seeking cost-efficient, flexible, and sustainable inspection solutions will find RoboCT to be a transformative addition to their non-destructive testing capabilities.
Conclusion
RoboCT represents the next generation of industrial computed tomography, combining robotic precision, advanced scanning capabilities, and digital twin technology to deliver high-resolution inspection of oversized and complex components. Its flexibility, efficiency, and cost-effectiveness make it an ideal solution for aerospace, automotive, energy, and other industries where quality and safety are paramount. By adopting RoboCT, manufacturers can enhance their quality assurance processes, reduce operational costs, and support sustainability goals, setting a new standard in non-destructive testing.
About X-Ray LAB Industrial Services GmbH:
X-Ray LAB specializes in industrial computed tomography and non-destructive testing solutions. Their RoboCT system is a groundbreaking innovation, enabling accurate and efficient inspection of large and complex components across multiple industries.
Frequently Asked Questions
What Types Of Components Can RoboCT Inspect?
RoboCT can inspect oversized and complex components that traditional CT systems cannot handle, including aerospace fuselages, automotive chassis, wind turbine blades, and large energy industry parts.
How Does RoboCT Achieve High-Resolution Scans Of Large Parts?
RoboCT uses robotic X-ray source and detector movement combined with digital twin planning. It can perform 2D scans for overview and targeted 3D scans for critical areas, ensuring high resolution and accuracy.
Can RoboCT Be Integrated Into Production Lines?
Yes, RoboCT is designed for inline and at-line inspection, allowing seamless integration into manufacturing workflows while maintaining automation and minimal manual intervention.
What Is The Role Of The Digital Twin In RoboCT?
The digital twin enables precise scan trajectory planning, monitoring, and automatic selection of optimal scanning strategies. It reduces errors and improves throughput.
How Does RoboCT Support Sustainability Goals?
By replacing multiple conventional CT systems with a single robot-based setup, RoboCT reduces energy consumption, operational costs, and environmental footprint, contributing to decarbonization initiatives.
