Detailed Overview
The Elios 3 UT Payload unlocks a new frontier — thickness measurements taken from the air, in places where ladders, scaffolding, and rope access used to stand in the way. Developed alongside Cygnus Instruments, it turns the Elios 3 into a flying ultrasonic gauge that delivers accurate thickness readings supported by high-resolution A-scans, even in harsh and confined spaces. What once took hours of setup and risk can now be achieved in minutes — reducing downtime, improving safety, and delivering repeatable inspection data.
Precise, Location-Tagged UT Measurements
When used together with the LiDAR payload, every UT reading is anchored to its exact position on a live 3D model. This allows inspectors to see where every measurement was taken in real time, track inspection coverage, and visualize results directly on a digital twin. Combined with the Asset Management software extension and Cockpit’s Live Map, spatial context becomes as clear as the data itself.
Smart Couplant Dispenser
The payload includes a remotely operated couplant dispenser that delivers just the right amount of gel for optimal ultrasound transmission. The operator can monitor remaining couplant and return for a quick refill or syringe swap when needed — no guesswork, no waste.
Smart Probe Arm
Designed specifically for drone-based UT inspections, the articulated probe arm intelligently positions the transducer onto the surface — adapting to contact angles, structures, and surface conditions — making reliable measurements possible in areas normally out of reach.
Modular Probe Head System
The UT payload supports interchangeable twin-crystal piezo-composite probes in 2 MHz, 5 MHz, and 7.5 MHz, making it effective on everything from thin pipes to thick, corroded steel. Echo-Echo capability lets you measure through up to 1 mm of coating without removing paint. Probe hoods are available to match different surface shapes, helping maintain optimal contact during flight.
Cleaning Module for Surface Prep
For surfaces covered in debris, dust, or corrosion, the probe head can be replaced with a cleaning module. Clean, tag the location, then return with the probe to perform measurement without losing precision or position.
Live A-Scan in Cockpit
On the operator’s screen, the Live A-Scan widget provides real-time UT displays with adjustable gain and gates, allowing both automated or manually refined readings — perfect for challenging surfaces, irregular coatings, or verification during flight.
Advanced Post-Processing
After the mission, Inspector 5 software turns captured UT data into actionable insights — allowing you to review, validate, analyze, and report with speed and clarity.
Built on Proven Technology
Developed in partnership with Cygnus Instruments, a pioneer in ultrasonic thickness measurement, the Elios 3 UT Payload brings decades of expertise directly into the air — merging trusted data accuracy with modern aerial capability
Integrated ultrasonic testing module for drone-based thickness measurement of structural integrity.
- This innovative payload allows the drone equipped with an ultrasonic transducer, taking a thickness measurement of the material (e.g., tank wall or pipe) without human entry.
- It is used for structural integrity checks in dangerous or inaccessible areas.
- The product is an ultrasonic thickness gauge module with a deployed contact mechanism that connects to the drone.
Top Features & Benefits
- Ultrasonic Thickness (UT) Payload
- Integrates with the Elios 3 drone
- Allows for contact-based thickness measurement
- Requires perching/landing
- Used for storage tank and pressure vessel
Primary Uses & Functions
An Ultrasonic Testing (UT) payload accessory for the Elios 3 drone used to measure wall thickness and detect corrosion at remote contact points in confined spaces.
Real-World Applications
- Enabling Ultrasonic Thickness (UT) measurement from the Elios 3 drone platform
- Performing spot-check corrosion monitoring on walls of tanks/vessels
- Reducing the need for scaffolding and human entry for UT checks
Industry Solutions
- Oil & Gas
- Petrochemical
- Power Generation
- Manufacturing
Technical Specifications
| Feature |
Specification |
| Probe type |
Dual element transducer (piezo-composite crystals) |
| Probe manufacturer |
Cygnus Instruments |
| Measurement Range in Steel |
0.8mm to 250mm1 |
| Measuring Mode |
Mode 2 (Single Echo) and Mode 3 (Echo-to-Echo) |
| Gain and Gate Control |
Automatic or Manual Gain and Gate Control |
| Accuracy |
±0.1 mm (±0.004”) or 0.1% of thickness measurement whichever is the greatest |
| Resolution Display |
0.1 mm (0.005”) or 0.01 mm (0.0005”) |
| Calibration Mechanisms |
Automatic V-path correction for twin crystal probes. Option of One or Two point calibration for twin crystal probes. |
| Gel acceptable viscosity |
1:1 mix of standard UT gel with water for optimal performance |
| Display |
Dedicated UT tab in Cockpit with A-scan display |
| Certifications |
RoHs, CE, FCC, FDA, IC (only for final MP) |
Modification from nominal specifications
| Flight time while hovering |
7min401
E3 + LiDAR Rev7 + UT with probe |
| Flight time in normal UT use (4 POM / Minute) |
7min2
E3 + LiDAR Rev7 + UT with probe |
Compatibility
- Accessory for the Elios 3 Inspection Drone System to perform Non-Destructive Testing (NDT) via contact Ultrasonic Thickness (UT) gauging.
- Requires a suitable contact surface within the confined space.
What’s In The Box?
Core module
Probe 2 MHz
Probe 5 MHZ
Probe 7.5 MH2
Cleaning module
Interfaces kit
Drone attachment kit
Extension kit
Gel kit
Spare smart syringe kit
SOFTWARE:
Cockpit integration
Inspector integration
SERVICE:
UT Online Training
**Dependent on the package chosen
Also Known As
UAV Thickness Sensor, Ultrasonic NDT Attachment, Aerial UT Probe
