An innovative approach to automating ultrasonic testing
Ultrasonic Sciences Limited (USL) based in Aldershot, Hampshire, UK are leaders in the design and manufacture of automated and semi-automated ultrasonic testing systems. Many of their systems are in use around the world testing highly critical metallic and composite components mainly in the aerospace and metals industries. When USL decided to manufacture a fully automated robot based system Stäubli Robotics was selected as their development partner.
For over 25 years USL have been designing and manufacturing bespoke ultrasonic testing systems. Their highly advanced systems generate process and store data which is used to produce detailed 3D computer images and is retained for reference as the testing data record of each component, as required for all critical components in aerospace and many other sectors. Their systems employ a range of techniques ranging from immersion systems where the component is held underwater and the ultrasonic probe transmits ultrasound through the water into the submerged component to through transmission squirter systems where the sound travels through a jet of water to the component and a second head precisely located on the opposite side of the component section detects the transmitted signal. This technique is particularly useful for testing composite structures where delamination and defective bonding could arise.
USL are manufacturers of fully automated ultrasonic squirter systems, particularly for applications where complex shapes needed to be tested, such as aircraft fuselages and turbine blades. For these applications the ultrasonic heads needed to be fully synchronized, normal to the testing surface and capable of being positioned very accurately on either side of the component. Movement to the next required location had to be quick and precise with the system providing full data capture, typically recorded at a rate of 2000 readings per second with data being retrieved every 0.5mm. Defects being detected range from around 100µm on jet engine turbine blades to 6mm/12mm on aircraft composite parts. To provide these precise movement sequences USL decided that multi-axis robots would be an attractive alternative solution to their existing range of gantry systems. Robots were readily available; capable of being programmed to follow precise trajectories were reliable and easily maintained.
Following a detailed review of the robot models and software available, USL selected Stäubli Robotics to provide the automation required. Stäubli six axis robots had the speed, accuracy of trajectory, precise movement; rigidity and reliability required and were reasonably waterproof. Most important of all was the Stäubli uniVAL drive interface that could be used in association with the Stäubli controllers.
Stäubli uniVAL drive is a totally new concept in robot system control having the flexibility and adaptability to synchronize any number of axes and any number of Stäubli robots in real time. This allowed USL to use their own programing systems and techniques to bring together into one control system not only the six axes from each robot but also the gantry movements as well as the ultrasonic squirter head, water pump and nozzle sequencing. Water flow needed to be adjusted to correspond to the contours of the test surface as well as compensating for the gravitational effects when operating at a higher level. Servos controlled both pumps and water jet angles. In total USL built a control system capable of handling up to 32 axes.
USL selected two Stäubli RX160 robots for the initial squirter ultrasonic testing system. This model provided the reach and rigidity required within a compact footprint capable of being floor mounted or suspended upside down. The robot design was inherently waterproof with all cabling being fed inside the arm; and protection levels of IP65 (IP67). Utilizing the flexibility of the uniVAL drive interface USL was able to control the complete system through their own bespoke controller.
Initial reaction to the new automated systems has been very good. Nigel Gray, Technical Director at USL commented, "Development of the fully automated ultrasonic squirter system has been easier than expected thanks to the operational adaptability of the Stäubli uniVAL drive and the intrinsic accuracy and robustness of the RX160 robots".
Automated ultrasonic systems offer considerable benefits to users. Traditional testing procedures which typically, including loading and unloading, take several hours can be reduced to just a few minutes, with the added facility of full and secure data capture. One testing sequence normally taking 4 hours was reduced to just 14 minutes when a robot based inspection was introduced.
Robotic systems are also easier to service and maintain significantly increasing availability.
The first applications of this new system will be installed in the USA for the testing of executive jet fuselages closely followed by the testing of other aerospace parts such as composite panels and jet engine turbine blades in the UK.
Other News from Staubli UK Ltd (Robotics Division)

Latest news about Robotics
- Universal Robots launches vast online knowledge bank
- IP44 robolink from Igus defies water
- Hire a robot from just £63.99 per day
- Igus demonstrates Robolink in splash water applications
- Robot range is quickly extended with the new 7th axis from Igus
- Re-energising European battery cell production
- Omron appoints Reeco Automation as solution partner for collaborative robots
- Cobots key to the future of manufacturing
- Universal Robots launches SME automation month for October
- A key consideration for a successful robot installation
- ABB offers Augmented Reality on a smartphone to simplify robot installations
- Long reach with a high payload: Fanuc expands m-900 series
- Robot palletiser increases throughput and reduces costs
- Fanuc expands range of handling robots
- ABB’s new 3D inspection robot system makes quality control testing ten times faster
- UK’s only dedicated Universal Robots training centre to reopen after Covid-19 lockdown is eased
- Automatica and Munich School of Robotics and Machine Intelligence (MSRM) initiate AI platform munich_i
- Cobots maximise return on investment
- Festo gives the future of safe automation a hand
- Omron launches HD-1500 mobile robot with 1500kg payload capacity
- New cobot offers solution for post-lockdown manufacturing
- Fanuc UK to host dedicated automation event for injection moulders
- RS Components joins forces with VEX Robotics to set summer STEM coding challenge
- ABB makes manufacturing more sustainable by recycling and remanufacturing thousands of old robots
- Entry-level robots to kick-start new factory automation projects
- Fast entry into low-cost automation using a digital twin in intuitive robot control
- UNLOCK A NEW LEVEL OF FLEXIBILITY FOR FINISHING APPLICATIONS
- Robots speed up the production of Covid-19 tests
- Collaborative robot brings game-changing industrial performance
- ABB’s robot training masterclasses now available online
- Universal Robots offers free online consultations to Pharma companies
- UR10 cobot from RARUK Automation saves labour costs at BWI
- Do you need a collaborative robot?
- RARUK opens dedicated Universal Robots training centre
- Robots play key role in the manufacture of EV battery packs
- Safe in the robotic arms of Mitsubishi Electric
- Tending to excel with a robot ‘handshake’
- Mitsubishi launches new robot model at SPS 2019
- Mobile robot moves payloads up to 250kg
- Collaborative or cooperative: which type of robot suits your needs best?
- New support offering helps to raise productivity
- Robot versus knot – it’s a tie
- LG Motion expands into collaborative robotics
- Food cutting becomes a piece of cake
- Mitsubishi introduces range of high performance delta robots
- Can robots transform your business?
- UK Robot Pioneers win Queen’s Award for Enterprise for Innovation
- British made robots already helping UK manufacturers
- New additions bring greater robot dexterity
- Robot arms are getting everywhere
- In the future you’ll be talking to your robots
- Innovation lab shows the benefits of robots
- New dresspack configurator for virtually any robot
- Three-way concept for tool changer for all robot brands
- Yaskawa and Reeco partner in cobots
- Igus introduces delta robots at under £5,000
- Universal Robots launches new flagship cobot range
- Applied Automation adds new cobot product lines
- New cobot offers flexible and reliable support
- Optimise your production
- Should robots pay taxes?
- Standards for safety when using collaborative robots
- Should robots be taxed?
- Fanuc launches SCARA robot range for assembly, packing and material handling
- Small and cost-effective: low-cost robolink robot arm in a compact design
- Cobot force control with high sensitivity
- Collaborative automation – a guide to common applications
- Universal Robots draw the crowds in Regent Street
- ABB extends the YuMi family
- Easy transition from ‘helping hand’ to full automation
- New White Paper: Cobots – a catalyst for reshoring
- Mitsubishi extends robot range with first collaborative robot
- Six-axis robot turns 3D printing into an art form
- Automata slashes the cost of robotics
- RARUK Automation highlights robots at Advanced Engineering
- Seminar provides step-by-step guide to improving your productivity with robots
- Dual gripper speeds output and relieves tedium
- Innovative Collaborative Robot sets new benchmark
- Omron debuts world’s fastest and first 4 arm Delta robot
- Resist the urge to blame the robots
- Schunk publishes its new lathe chuck catalogue
- New collaborative robot products and applications showcased at Northern Manufacturing
- Yaskawa MotoLogix hooks up with Routeco
- Universal Robots receives ‘Best Design’ award
- Mabey puts cutting-edge ABB robots to work
- Motoman robots plus AirGrip equals a better grip on bottles
- New robot lends precision and reliability to the production of hearing aids
- One stop shop for robotics and motion
- The future is bright for robotics
- A simple guide to robot safety
- Free online training in robot programming
- Cobots driving efficiency improvements
- Low-cost robotic range simplifies complex tasks
- Collaborative robots provide burger flipping assistance
- Low cost robotic range from RS Components
- Simple guide to robot safety
- Universal Robots now certified for cleanroom applications
- Cobots key for product testing
- Open source robotics
- Low-cost robotic range available from RS simplifies complex tasks
- Seminar provides step-by-step guide to improving your productivity with robots
- Igus expands robolink D modular kit with plastic gearing
- Universal Robots racks up the benefits at Etalex
- Igus robolink D 5-axis articulated arms now available pre-assembled
- RARUK Automation appoints robot sales engineer
- Twin robots learn to live and work with each other
- Yaskawa investing in Europe for future growth
- Igus extends robolink with direct drive arms
- Universal ‘co-bots’ boosted by next-generation robot programming
- Igus humanoid open platform robot
- UCB life scientists use robots to test cells by the billion
- X-STK confirmed as Preferred Partner for Universal Robots
- ABB Robotics introduces Connected Services to improve UK productivity
- Hands up if you know one robot arm from another
- Harder, better, faster
- Robot programming via PLC is key in food plant
- Benefits of Rodriguez-supplied technologies filter through at FDC
- Delta robot with open-architecture controller
- Teradyne announces new Universal Robots president
- Universal Robots now certified for applications in cleanroom environments
- Robot automates SIM card packaging
- Low cost robots help students get up to speed
- Collaborative robots meet machine tending needs
- Igus robolink robots tend machine tools
- Omron acquires Adept’s classy robots for fast-moving automation
- Collaborative robots boost production and prevent errors
- Foodie fads spark robot rethink
- UCB life scientists use robots to test cells by the billion
- The breakthrough of smart robots at Automatica 2016
- ABB to showcase latest robotic innovations at MACH 2016
- ABB introduces its first SCARA robot family
- Mitsubishi demonstrates MELFA SafePlus robotic safety
- From distributor to preferred partner
- AUTOMATICA 2016: Innovations for the food industry
- Applied Automation to distribute Universal Robots
- Second tea packing system ordered
- Second tea packing system ordered
- COMAU and B&R assimilate robotics into machine control
- London start-up simplifies robotic automation at a 10th of the cost
- Life sciences focus for AUTOMATICA 2016 in Munich
- 10,000 Comau robots controlled by B&R
- Modular system for safe robotics
- Path tracing robot with pattern recognition
- Safety considerations with CoBots
- Direct drive robotic arms support lean automation
- Omron acquires Adept Technology
- Fanuc robotic golf cell highlights precision and vision
- Omron demos path tracing delta robot with freehand pattern recognition
- Robot delivers 18 month ROI
- First Fanuc MC410iC/185 robot in the field at Askew & Barrett
- Aerotech introduces RCP-DELTA robot and controller
- Fanuc unveils world's highest payload collaborative robot
- Robots are on the march
- Schunk has a hand in precision gripping
- Unlocking the potential of robotic automation
- Robot 'first timer' meets exponential growth in demand
- Superior operating performance and reduced operating costs
- Sweetcorn Factory First for FANUC
- Busting the myths around robotics
- ABB acquires Gomtec to expand collaborative robotics portfolio
- Igus to offer €1500 industrial robot
- Teradyne announces Universal Robots acquisition
- Flexible product gripper
- Flexible, light-weight table-top robot
- Lightweight, table-top robot for collaborative working
- Getting a grip on collaborative robots
- Putting safety first when working with robots
- Robotics in the supply chain will enhance humans, not replace them
- Browse robot videos by company, technology or industry
- Robotics update brings the best of the web
- Using robots for bespoke and low volume processes
- robolink helps robots break free
- En route to robot safety
- Measuring robot works tirelessly outdoors
- Adaptive robot gripper system
- RA Rodriguez introduces third generation robots
- Robot gripper based on the human hand
- Tiny gripper accomplishes 3mm stroke in 0.03s
- HANNOVER MESSE showcases latest generation of industrial robots
- Picked to perfection
- Top tips for staying safe when working alongside robots
- Universal Robots launches third generation products
- New resource for industrial robot information
- Lightweight robots incorporate absolute encoders and adjustable safety
- Service robots revolutionise clean-up of the Sydney Harbor Bridge
- "Farming intelligence" creates greater value
- AUTOMATICA 2014: Focus on automobile production
- Innovations in life sciences
- Robots for metalworking
- Service Robots - Clever colleagues at work
- Service Robots - intelligent and autonomous
- Service robots in the medical industry
- Working with robots simply as automation components
- Table tennis star takes on fast, flexible KUKA robot
- Improving the state of UK manufacturing
- Mitsubishi Electric robot emulates intuitive human cake icing movements
- Universal robot is a star attraction at Honda's Technical Festival
- The brains behind an effective robot solution
- The robot revolution that never quite happened...
- Table tennis legend to take on KUKA robot
- Robot transformations
- FANUC paint shop robots boost installed UK base
- An innovative approach to automation for production of airbag control sensors
- KUKA announces Siemens cooperation
- How to take control of a robot arm
- Next generation of high speed pickers
- Robot helps to get MS sufferer back to work
- Mitsubishi Electric robot picks stem cells
- Novel energy chain system increases uptime for Jaguar Land Rover
- Performance robot is food safe
- Robotics integrates with vision, motion and PLC in single platform
- Innovative robot design set to revolutionise the market
- Increase production flexibility with a robot arm tool changer
- Transforming your sustainability with robotic automation
- Huge uptake reported for automation grant
- Innovation in lightweight, low cost robotics
- Automation Brings Everything Together in the Electrical Industry
- ABB doubles investment in training centre
- Getting to grips with the bionic FinGripper
- Pick and place delta robots
- Robot night shift gives ALM a competitive edge
- Seeing your name in lights, thanks to KUKA robots
- Economical, flexible robot found after 10 year search
- Aerotech launches Cartesius T-style robots
- Automation transforms forge's finishing facility
- Compact high-speed robot requires minimal workspace
- It's time for the UK to embrace robots
- Modular robots were inspired by nature
- Robot arm tool changer is faster and stronger
- Robot range completed by six-axis launch
- Robot retrofits: Axis 1 safety
- Save assembly time and costs
- ABB robots featured in "Terminator Salvation" movie
- Bionic penguins mimic real life movement
- Energy and data supply for robotics