Meet the COROB Open Call Winners: Interview with HYPER ROBOT
What is the solution?
HYPER ROBOT is a high-precision radar-based sensor system designed to measure weld bead height in real time during robotic welding processes. It enables less than 0.05mm accuracy even in harsh industrial environments where optical systems fail, ensuring consistent weld quality and zero-defect production. The system integrates seamlessly with industrial robots via standard APIs and supports edge processing with AI-driven algorithms for real-time feedback and decision-making. Its compact design, robust performance, and low maintenance requirements make it ideal for advanced manufacturing and Industry 5.0 applications
What makes it novel:
Unlike conventional inspection or sensing systems (optical cameras, laser scanners, ultrasonic sensors), HYPER ROBOT uses high-frequency radar, enabling reliable measurements even in harsh industrial conditions — including smoke, dust, varying lighting, or other visibility-challenging environments.
- It delivers >0.05mm enabling fine control of weld bead height and alignment with extremely tight tolerances.
- The system combines radar sensing, embedded signal processing/AI, and direct robot-API integration. This means measurements are not only captured but processed and fed back in real time enabling dynamic adaptation.
- Its compact, modular hardware design (with interchangeable 3D-printed or dielectric-lens antennas, small radar-SoC + MCU board, and flexible interface board) allows for easy integration into different robot heads or configurations, making the solution broadly adaptable across many robot types and industrial settings.
The system supports modern industrial connectivity (serial, UART/RS485, optional edge-gateway via Raspberry Pi + MQTT) and offers a comprehensive software stack with GUI visualization, calibration and logging combining measurement, monitoring, maintenance and data export in a single packaged solution, rather than requiring multiple disparate tools.
What motivated you to apply for the COROB Open Call?
It aligns directly with our mission to advance precision sensing technologies for industrial automation. The program offers a unique opportunity to validate and demonstrate our high-accuracy radar sensor solution for welding robotics in real-world environments. We see COROB as a strategic platform to collaborate with leading industry players, access expert mentorship, and accelerate the deployment of our technology across European manufacturing ecosystems. The program makes an ideal environment to refine our product, validate new use cases, and build strong commercial pathways.
How do you envision your project making an impact?
Impact by transforming precision control in robotic through radar-based sensing. Unlike traditional vision systems, our radar technology delivers micrometre-level accuracy in real time, even in challenging industrial environments with smoke, reflections, or poor lighting, conditions where optical systems often fail. Our system reduces defects, improves quality assurance, and boosts automation efficiency. This directly contributes to more sustainable manufacturing by minimizing rework, material waste, and downtime. At scale, our technology can redefine how industrial robots perceive their environment, extending to broader use cases like adaptive path planning, contactless metrology, and quality inspection.
