Weld Seam Inspection Without Compromise
Project Duration: 01.07.2025 – 31.12.2027 | Project Partner: b-automated | Funder: Central Innovation Programme for SMEs (ZIM)
Objectives
Manual inspection processes for spot weld joints are time-consuming, labour-intensive and partly destructive. The research project ROBO-KMU4.0 replaces these outdated methods with a fully automated, non-destructive ultrasound system featuring AI-based evaluation, reducing the inspection time of an entire car body from up to one week to under 24 hours while significantly lowering personnel requirements.
- Automation: Development of a manufacturer-independent system for various body shapes, material combinations and welding patterns.
- Technology: Use of a miniaturised end-effector on a 6-axis industrial robot combined with high-precision sensors, real-time ultrasound inspection and AI-based image processing.
- Software: Handling of path planning, measurement time optimisation and 3D storage of weld points.
Results
The centrepiece of the solution is a miniaturised end-effector mounted on a 6-axis industrial robot operating with an ultrasound sensor.
The robot moves precisely to each weld point, transmits ultrasound signals and evaluates them in real time using an AI algorithm. The results are stored and visualised in a data-driven manner.
Industrial Benefits
- Non-destructive testing: No more rejects due to destructive inspection methods.
- Speed: Inspection time reduced from up to one week to under 24 hours.
- Personnel costs: Significant reduction through automation of inspection lines.
- Data-driven quality assurance: Full traceability of every weld point throughout the entire product lifecycle.
- Market: The primary target group is the automotive industry, which faces high economic losses due to destructive inspection methods.
Significance
The ROBO-KMU4.0 project demonstrates S4P expertise at the intersection of industrial digitalisation, AI and automation. The insights and technologies gained can be integrated into existing S4P solutions (MES, APS, Quality Assurance, Real-Time Process Control) to provide scalable, data-driven inspection processes for mid-sized manufacturing companies.
Publications
Publications related to this project can be found under Publications.
Are you interested in AI-based quality assurance or automated weld seam inspection? Contact us – we will discuss together how ROBO-KMU4.0 can optimise your manufacturing process.