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XRHRobotStar: High-volume in-line inspection

Press Release   •   Jun 01, 2018 12:11 GMT

The XRHRobotStar is a digital X-ray robot-system that allows an ultra-fast in-line inspection. The innovative Automated Defect Recognition (ADR) and optimized process make it the fasted in-line system worldwide. The throughput can be increased by using a cluster of several systems.

The underlying principle is that a loading robot on the outside handles the incoming parts and distributes the inspected parts, while the robot on the inside has a C-Arm with mounted X-ray components. The acquired images are automatically processed by the in-house developed ADR and checked for critical defects or other user defined criteria. The patented system is Industry 4.0 ready and used mainly by automotive suppliers with high production volume.

This system is innovative in many different ways. First of all, VisiConsult was granted a patent for its novel operation principle. The highly parallelized setup allows shortest cycle times. As an example: A medium sized casting part of roughly 500 mm has a total cycle time of 16 seconds with a total amount of 10 test positions. VisiConsult as a solution provider for customized X-ray systems adapts the system directly on the existing manufacturing line for every customer. Below are the main innovation areas:

Flexibility: VisiConsult just registered a patent for the revolutionary concept of combining a 3D stereo-camera with an automated X-ray system. The camera notes the offset towards the reference position for every part and allows the robot to automatically track the part. Combined with a novel image registration and robust ADR algorithms this innovation eliminates the need for expensive and inflexible part holders.

Industry 4.0: The system is fully interconnected and embedded to the ERP/MES systems of the customer. With single part traceability the system is therefore even fulfilling demanding automotive or aerospace standards. Operators can pull up specific images at any time. Inspection data can also be used for process optimization. The knowledge of specific defect distribution is a valuable insight, which can be used by process engineers.

Automation: Of course, physically the system is completely automated and designed to run 24/7 without human interaction. But more important is the digital side of the system. The in-house developed Automated Defect Recognition (ADR) is able to fully evaluate the acquired images. Typical casting defects like porosities, inclusions and geometry deviations are detected and measured. A broad variety of criteria, which can be defined by the user, can be used as a threshold.

The specialist for customized X-ray inspection solutions and automation

VisiConsult is a family owned company located in Northern Germany and the leading specialist for customized X-ray inspection systems. To ensure the renown premium quality all products are developed and produced locally in Germany as turnkey solutions. This leads to cutting edge technology and a high flexibility. Being active in several fields like Non Destructive Testing (NDT), public Security and the electronics manufacturing industries VisiConsult offers a sophisticated product portfolio.

The company philosophy is to solve the customer's inspection problems with tailored solutions combined with a premium post-installation service and support. More than 25 years of expertise in Automatic Defect Recognition (ADR) and image enhancement for a broad variety of industries combined with experienced engineers result in solutions that set new industry standards. VisiConsult is always looking forward to new challenges and is proud to be known as a reliable partner with sustainable products. Through an international network of trained representatives all around the world a reliable first-line sales and service network is spanning the globe.

VisiConsult X-ray Systems & Solutions GmbH

Brandenbrooker Weg 2-4
D-23617 Stockelsdorf, Germany

Phone: 0049 (451) 290 286-0
Fax: 0049 (451) 290 286-22


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