Ultrasonic Testing Process Package
HedraCAM ultrasonic testing process package provides complete offline programming for dual-robot collaborative ultrasonic inspection, supporting multi-robot and dual-tower 5-axis structures, covering the full workflow from surface modeling, path planning, collision detection to post-processor output. Successfully applied in NDT scenarios for aircraft components, rail transit, wind turbine blades and other high-end equipment.
🔧 Core Package Features
Surface Repair & Path Extension
Pre-processes gap surfaces to generate complete inspection paths, supports extending in four directions to ensure smooth line transitions outside the workpiece surface, avoiding artifacts in C-scan imaging
Intelligent Program Segmentation
When large workpieces generate excessive path points, the software splits the complete path into multiple sub-programs at designated segmentation points. The robot executes via sub-program calls, bypassing single-program capacity limits without affecting imaging quality
Rail Auto-Assignment
Rail positions are automatically assigned based on path point locations during import, eliminating manual data entry and significantly reducing planning time. Manual override for specific zones is also supported to avoid abnormal robot poses
Program Point Mirror Flip
In dual-robot inspection scenarios, paths created on one robot can be mirrored along a specified axis to directly generate path files and rail values for the second robot, substantially cutting debug time on the second machine
Multi-Brand Robot Support
Supports KUKA and other mainstream industrial robot post-processors, optimized code generation for each brand's specific control system to ensure seamless integration with on-site robot controllers
Dual-Robot Synchronous Simulation
Supports dual-robot mirror path generation with synchronous simulation verification, real-time collision risk and workspace overlap checking for large workpiece bilateral inspection scenarios
🎯 Technical Challenges & Solutions
Complex Surface Normal Tracking
Probe maintains perpendicular orientation to workpiece surface at all times, path points generated along surface normal automatically. Both robots sync normal tracking on each side, ensuring detection coverage on complex curved surfaces such as turbine blades and dome heads
Precise Step Distance Control
Equidistant trajectories ensure uniform C-scan image line spacing; path density auto-refines at high-curvature regions. Step distance balances detection resolution and inspection efficiency to eliminate missed areas
Multi-Axis Coordinated Motion
Supports robot + rail + positioner multi-axis coordination, path point coordinates directly assigned to rail axes for large-size, complex-pose workpieces. Dual-rail error compensation models built separately to prevent phase shift causing beam axis misalignment
Complete Guide Path Planning
Automatically plans complete guide path from origin to entry point with full trajectory visualization, ensuring safe robot approach to the inspection zone
Automatic Surface Repair
For workpieces with holes, supports automatic small hole exclusion and surface UV filling to ensure uninterrupted continuous paths and prevent scanning interruption
Collision Detection & Reachability Analysis
Automatically identifies singular points, interference points and unreachable points before simulation, reducing on-site debugging. Also checks collision risks in overlapping dual-robot workspaces
📹 Application Videos
Ultrasonic Testing Application Cases