ZEISS Research & Quality Solutions (ZEISS RQS) has introduced ZEISS TALOS, a metrology robot for automated, high-volume inspection. The system combines metrology-grade accuracy with robotic kinematics and, according to the company, delivers measurement uncertainty below 100 µm over a reach of 3.30 meters.
ZEISS says the system positions its sensor precisely and repeatably without external tracking systems or reference markers. That capability is intended to support reliable measurement of medium-sized and large components, including areas that are difficult to access with conventional line-of-sight measurement systems.
Robot and sensor form one measurement unit
The metrology robot ZEISS TALOS MR and the compact blue-light sensor ZEISS TALOS AX form an integrated measurement unit. The package also includes the metrology-grade ZEISS TALOS RT rotation table and the ZEISS TALOS Safeguard safety concept.
Dr. Jan Thesing, head of the Business Unit 3D Optical Systems at ZEISS, said the system represents a fundamental shift in automated metrology because metrological capabilities are integrated directly into the system while the speed, range and flexibility of robotic kinematics are retained.
One sensor for surfaces and features
ZEISS describes a longstanding challenge in optical metrology as combining fast surface measurement with precise feature measurement. The TALOS AX sensor uses two 24-megapixel cameras and captures images at 100 Hz, or up to 200 Hz in a fast-scan mode.
With a 500 mm wide measurement volume and four multidirectional feature flashes, the sensor is designed to measure large surfaces for geometry analysis and digital twins as well as precise features such as holes, edges, bolts and threads. A newly developed optical sensor allows full-field geometry acquisition and precise feature measurement within one automated workflow, according to ZEISS.
Designed for production environments
The robot and system concept are designed to withstand common environmental influences such as temperature variations, vibration and dust. Measurement tasks can be prepared offline using the CAD model, while ZEISS INSPECT automatically calculates the required measurement positions and robot paths.
ZEISS says this can significantly reduce the time and effort needed to plan new measurement tasks. One-click programming, efficient robot motion and streamlined setup are intended to increase throughput and make more efficient use of measurement capacity. With ZEISS INSPECT, users can carry out complete analyses, generate reports and integrate measurement results into existing processes.
Applications in vehicle and aerospace manufacturing
ZEISS TALOS is designed for automotive, aerospace and commercial vehicle manufacturing applications, both near production lines and in dedicated measurement rooms. The system supports inspection tasks ranging from car bodies, hang-on parts and giga-casting parts to aerostructures, jet engines, truck cabins and weld seams.
High-resolution measurement data is intended to enable precise evaluation of component quality and deviations. Virtual tools can be used to assess functional dimensions, gap sizes and flushness, for example in automotive assembly.