Robotic measuring system for ultrasonic testing
Efficient ultrasonic testing using digital twins — from simulation directly to real measurement. With innovative software for simulation and test generation based on digital twins, we are revolutionizing ultrasonic testing: A robot-guided ultrasonic sensor automatically scans 3D components. Our RobSimulation software analyses CAD data of the component, automatically derives the optimal measurement points and creates the complete test task from this. This is virtually simulated, optimized and fed directly into the robot system.
Efficient ultrasonic testing using digital twins — from simulation directly to real measurement
The challenge:
Ultrasonic testing of composite aircraft components is complex, time-consuming and has previously required complex, manual programming of robot movements. Each new component requires a great deal of planning and commissioning — a clear bottleneck in quality assurance.
The solution:
With our innovative RobSimulation Software Is the test task complete for the first time Digitally prepared:
From the CAD data The required measurement points are automatically generated for the components. From this, the software creates a digital twin of the testing process, simulates the optimal robot movement and transmits the determined sequences directly to the real robot system.
This creates a seamless transition from virtual planning to real execution — Without manual reprogramming.
The results:
- Fully Automated Generation and Simulation of Test Procedures
- Direct Transfer of Optimized Test Sequences to the Robot
- Virtual Start-Up with Real Execution
- Significantly reduced process times and costs
- Higher flexibility and quality in non-destructive testing
With RobSimulation, you save time, reduce costs and increase efficiency — from digital idea to real measurement.
Battenberg presents at Airtec 2025 in Augsburg For the First Time, His New Measurement Robot for Ultrasonic Testing of Aircraft Composites — Demonstrated on a Helicopter Shell
Visit us Battenberg ROBOTIC from October 22-24 at booth N6500.
Benefits
- REPRODUCIBLE MEASUREMENT METHODS lead to validatable measurement results
- ECONOMICALLY thanks to modular, scalable expandability to many measurement tasks
- EASY TO USE via quick and easy graphical programming
- COST AND TIME SAVINGS through automation, simulation, and repeatability
- FLEXIBLE via parameterizable actions to program individual measurement processes
- VARIABLE in the exact orientation of the measurement robot on complex test objects
Overview of all use cases
For over 40 years, we have been developing and supplying measurement robots for reliable quality testing of their products for our international customers. High-precision measurement, analysis and evaluation of product specifications and characteristics is required.
In the application, quality ratings and product approvals are carried out more securely and faster in the audit process, along with significant cost reductions and competitive advantages.
Overview of all industries
Automotive
Battenberg Robotic Measuring has been testing vehicle components in research, development, production and end-of-line assessments for over 40 years. The results are used for cause-effect analysis and quality improvement. The areas of application are determined by the requirements of the specifications, the test tasks and environmental conditions.
Aviation
Medical
In order to meet quality and functionality standards, medical devices are subject to strict conformity assessments. The Battenberg Robotic Measuring is used to validate functional tests.
Lifestyle
The determination of functional haptic and optical reviews of lifestyle products by physical measurement variables is the task of Battenberg Robotic Measuring.
Reference customers
