Complex Robotic Ultrasonic Inspection Methods

About the Project

Rolls-Royce is exploring the implementation of robotics within manufacturing. One of the areas of robotic implementation lies within NDE. To enable the successful implementation of robotic NDE within the factory, complex geometries need to be inspected. The NDE method of interest is Ultrasonic Testing, this includes Phased Array Ultrasonic Testing (PAUT). This will require path planning tools to be developed and methods of mapping the ultrasonic signals throughout the components under inspection. Both In-series and traditional contact NDE methods should be covered.

While robotic platforms have been introduced to improve access, repeatability and accuracy, current implementations largely rely on pre-programmed, offline-generated scan paths derived from CAD models. These approaches assume idealised conditions—repeatable machined or manufactured geometry, stable coupling, and consistent probe orientation—which are rarely achieved at the point of manufacturing. Recent advances in robotic NDE have demonstrated sensor-driven guided inspection, and limited forms of adaptive sensing. For example, the custom MATLAB toolbox developed by Mineo et al. at the University of Strathclyde.

However, there remains a lack of a novel system that can couple adaptive robotic path planning, probe orientation, coupling constraints all under PAUT real-time feedback. As a result, robotic ultrasonic inspection has not been fully realised in industry production as manufactured parts due to the presence of geometric uncertainty, positioning errors, and variable surface conditions. Addressing this research gap is essential for enabling truly autonomous and reliable robotic NDE.

Research Aim

This project aims to develop a real-time sensor-enabled and adaptive robotic path planning tool, driven from ultrasonic NDE, capable of generating and dynamically updating inspection trajectories of complex or uncertain geometries while maintaining inspection quality, coverage, and efficiency.

Research Environment

The successful candidate will be based at Rolls-Royce in Derby in the Inspection Maintenance and Repair Services department (IMRS). The student will gain industrial experience working on real world problems with access to a range of NDE equipment and knowledge from experts in the field. The student will also spend time in the newly established £2.1M Sensor Enabled Automation & Control Hub (SEARCH) laboratory, collaborating with a team of over 40 researchers and PhD/EngD students for research and training purposes. The lab is equipped with state-of-the-art sensors, industrial robotics, and welding technology.

Beyond the technical research, the student will have access to industrial technical training courses, including LabVIEW Real-Time Programming, Fanuc Advanced Robot Programming, and Ultrasonics. Additionally, the University’s Research Development Program (RDP) will support skill development in key areas such as presentations, conferences, and journal writing.

This EngD offers full coverage of tuition fees for UK Nationals, along with a competitive stipend (plus an industrial top-up) and significant funds for equipment and travel throughout the project.

Contact Details: In the first instance, interested applicants should contact Dr Charalampos Loukas (charalampos.loukas@strath.ac.uk) and Professor Charles Macleod (charles.macleod@strath.ac.uk) with a cover letter and CV