Contactless quality control with radar allows for the inspection and measurement of an object both externally and internally without causing any damage. Fraunhofer FHR has been fine-tuning existing radar systems and developing groundbreaking new radar technology for over 50 years. Radar is an indispensable tool in the field of non-destructive testing due to its capabilities such as material depth scanning, independence from dust and steam, and high sensitivity to changes in distance. Its applications are diverse, ranging from detecting foreign objects or contaminants in food to ensuring the thickness of adhesive layers or measuring plate dimensions.

Fraunhofer FHR aims to deliver integrated, customized solutions for all industrial clients, optimizing costs, development time, and techniques used. A central focus is the integration of sensors into the production process. By forming alliances with partners both within and outside the Fraunhofer-Gesellschaft, a wide range of different sensors and measurement methods is available. Multispectral sensor concepts even enable solutions for tasks that were previously unmanageable with conventional quality control systems. In addition to identifying and visualizing product defects, Fraunhofer FHR's modern high-frequency systems offer inline monitoring of the entire production process, even at high line speeds.

SAMMI and µRADAS: Non-Destructive Testing in Process Control from Food to Steel Production to Plastic Extrusion

At WCNDT, Fraunhofer FHR will showcase two systems for non-destructive testing in process control: SAMMI® and µRADAS. SAMMI® is a millimeter-wave scanner measuring 40 x 40 x 30 centimeters, capable of inspecting objects up to 30 x 30 x 5 centimeters in size. Technologically, there is no size limit for the device. In SAMMI®, the object to be examined is placed on a conveyor belt and passed through the device. Above the belt, the monostatic transmitting and receiving antenna rotates. Possible foreign objects in the examined item are displayed in real-time on the device's screen.

In contrast, µRADAS is more resource-efficient and suitable for use in inaccessible locations as needed. Due to its smaller size, it can be used, for example, at the guide rolls in steel mills, where it can accurately measure the width and thickness of slabs in real-time with data processing and imaging.

Waste4Future: Sensor Suite for Improved Plastic Recycling

Fraunhofer FHR also demonstrates the capabilities of its radar sensors through the Waste4Future project at WCNDT. In Waste4Future, seven Fraunhofer Institutes are working on optimizing the sorting of plastic waste for better recycling possibilities. The goal is to achieve over 90 percent purity in separating so-called "shredder light fractions." Currently, plastic shreds are typically inspected only with an infrared sensor. Waste4Future employs a sensor suite for improved sorting: by combining infrared, thermography, ultrasound, and terahertz sensors, sorting quality can be maximized.