Improving Ultrasonic Wall Thickness Measurement with Automated Transducer Positioning

Ultrasonic wall thickness measurement is widely used to evaluate wall thickness and inside diameter in extrusion processes, but effective deployment often depends on precise transducer alignment. Traditionally, this alignment is performed manually during startup and product changeovers, requiring operator skill and repeated adjustments to achieve optimal signal quality.

In many production environments, manual centering can take too long, delaying startup while generating unnecessary scrap. When frequent changeovers occur, slow startup makes ultrasonics impractical.

Other alignment solutions use guide blocks, which must be perfectly sized, and even then can cause friction, leading to extrudate pulsation, abrasion, and occasionally breakage.

The new AutoPilot™ positioning system from LaserLinc was developed to address these challenges by removing manual centering and eliminating guide blocks from the ultrasonic measurement process. Designed as an accessory for LaserLinc’s UltraGauge™ ultrasonic systems, the AutoPilot system automatically positions the transducer assembly to align with the product, ensuring optimal signal strength and consistent measurements.

In initial production testing, the AutoPilot system consistently achieved proper alignment in under a minute, compared to extended manual adjustment times. By automating transducer positioning, the UltraGauge with AutoPilot solution reduces startup time and eliminates operator-dependent variability, making ultrasonic measurement even more effective and practical where it otherwise wasn’t.

The AutoPilot system uses motorized positioning and adjustable roller guides to center the product within the ultrasonic field without the need for fixed inserts. This approach avoids part abrasion, reduces wear components, and supports a wide range of product sizes without reconfiguration. Manual override controls are included to maintain flexibility when needed.

As manufacturers seek to reduce startup costs and improve measurement reliability, an automated positioning system such as AutoPilot™ enables ultrasonic inspection to become faster, more repeatable, and more scalable for modern extrusion operations.