It was a significant day for the future of railway maintenance. This was the prevailing sentiment on Thursday, January 31, at the conclusion of the presentation event for the USBOT System, developed by PCM.
Approximately fifty professionals attended the event, organized at the regional CIFI headquarters, where the new collaborative robot, created by the SAGA Group, demonstrated its full potential. Engineer Daniela De Marco succinctly summarized the impact of the system: “To inspect the 70,000 welds in the RFI network verified annually using the current manual method, 23,333 hours are required. With the USBOT System, this figure drops to 5,833.” In other words, it translates to a 75% reduction in inspection time or a 400% increase in inspected welds.
The USBOT System is capable of automating the inspection of railway track welds, both aluminothermic and flash-butt, using a phased array ultrasonic system managed by a collaborative robotic arm that continuously monitors applied pressure. This technology enables the precise identification of all typical defects in rail joints. Designed to be easily operated by just two technicians, the system minimizes human error and, thanks to advanced algorithms, provides immediate and accurate results, thereby enhancing the safety and reliability of railway infrastructure.
Following the opening remarks by Engineer Valerio Giovine, Secretary General of CIFI Rome, and Dr. Marco Salciccia, Technical Director of SAGA Srl, Glauco Francesco Patelli, Technical Manager of the PCM Institute, delivered a presentation on the history and evolution of the institute. The PCM Institute was established to meet the SAGA Group‘s need for continuous training and updating in Non-Destructive Testing (NDT) for railway maintenance. Over time, the institute has expanded to include research activities, from which the USBOT System originated. Operating sites are located in Ravenna and Scurcola Marsicana (L’Aquila). Recognized by the Italian Welding Institute (IIS), the center offers training programs for various inspection techniques, including visual testing, liquid penetrant testing, magnetic particle testing, ultrasonic testing, and phased array.
Engineer Emanuele Gandolfo, representing the Italian Welding Institute, elaborated on the certification process for NDT personnel, explaining that it is governed by the UNI EN ISO 9712 standard and is based on four key pillars: “training, physical suitability, industrial experience, and examination.” Gandolfo emphasized that ANSFISA guidelines, specific to the railway sector, have integrated this standard with industry-specific requirements, defining applicable inspection methods, access criteria, and standards for training and examination centers. The PCM Institute was authorized as a Training and Examination Center between March and August 2023.
A practical example illustrated the steps required to obtain Level 2 UT certification with the Phased Array technique, an essential qualification for operating the USBOT System. Candidates must complete theoretical and practical training, acquire documented industrial experience, pass visual tests, and undergo specific examinations. As highlighted during the presentation, “experience must be formally documented to the Certification Body through a logbook.” Only after these verifications does the Certification Body (CB) issue the final certification.
A particularly relevant contribution came from Engineer Giovanni Amarante, from the RFI operational management at Ferrovie, who described the ongoing USBOT System trial, highlighting its primary objectives: “automating inspections to enhance efficiency and objectivity in controls.” The inspections cover visual, geometric, structural, and ultrasonic aspects, all conducted using precise methodologies and defined timeframes. Amarante further specified: “Aluminothermic welds are inspected within 60 days of execution” and “all flash-butt welds are inspected within 90 days of execution.”
The trial aims to assess data reliability and field operability through comparative testing between inspections performed with the USBOT System and those conducted manually by certified personnel. The goal, as stated, is to achieve “reliable and timely validation of executed welds, enabling immediate replacement of any defective welds, thereby improving infrastructure reliability.” Engineer Amarante underscored the importance of inspection repeatability, a fundamental element in ensuring quality and safety.
Bureau Veritas Rail played a central role in evaluating the testing procedure. A leading company in certification, verification, and inspection services, Bureau Veritas has operated in Italy since 1839 and has been active in the railway sector since 1987. Bureau Veritas verified the entire process conducted by PCM, comparing it quantitatively and qualitatively against RFI Procedure requirements for conventional systems. As explained by Cristian Veglia, Rail Business Unit Manager at Bureau Veritas, the evaluation included “monitoring the repeatability tests of the USBOT System at the PCM laboratory” and “assessing the test results and related reports for completeness and adequacy in meeting the applicable RFI Procedure requirements.”
Bureau Veritas oversaw all trial phases—setup, execution, and post-processing—to ensure compliance with EN 17025 standards, with particular attention to personnel competence, technical equipment, traceability between calibration certificates and instruments, sampling, and result validity. At the conclusion of the process, Bureau Veritas stated: “Bureau Veritas Italia – Rail has determined that PCM S.r.l. has demonstrated an adequate management system for testing execution, ensuring personnel competence, independence, and result reliability in accordance with the principles outlined in EN 17025.”
The event concluded with a live demonstration of the USBOT System‘s operation, during which Engineer Daniela De Marco illustrated its operational phases. After positioning the robot and cleaning the target area, the operator launches the dedicated application, a digital control center where inspection data is input and recorded. The scan, lasting only a few minutes, concludes with the application of a QR Code label, allowing access to the complete report. The digital recording and archival of results, easily retrievable over time, represent a key strength of the system, ensuring speed, objectivity, and process repeatability.
De Marco also explained the function of the phased array probes, highlighting how they enable the analysis of significant material sections without moving the probe, thanks to the ability to electronically steer, rotate, and focus the beam at different depths. The inspection is divided into four distinct phases: in phase P₁, the head, web, and foot center are scanned with an angled beam from the rolling table; in phase P₂, the web and foot center are scanned with a straight beam from the rolling table; phase P₃ involves scanning the head with a straight beam from the rolling table; finally, in phase P₄, the foot is scanned with an angled beam from the clamping planes.
Special attention was given to operator safety. The USBOT System features a collaborative robot equipped with load cells, designed to continuously monitor applied pressure during scanning and prevent any risk to personnel.
The day concluded with the awareness that the USBOT System represents a major innovation in railway maintenance. By automating inspection procedures, the system enhances efficiency, quality, and safety, contributing to the robustness and sustainability of railway infrastructure.
