ZEISS Research & Quality Solutions (ZEISS RQS) has introduced ZEISS TALOS, a metrology robot intended for automated, high-volume inspection. The system combines metrology-grade accuracy with robotic kinematics and is designed to measure medium-sized and large components while positioning its sensor precisely and repeatably without external tracking systems or reference markers.
ZEISS says the system delivers measurement uncertainty below 100 µm across a reach of 3.30 meters. That combination is intended to support reliable inspection of parts and areas that conventional line-of-sight measurement systems can find difficult to access. A newly developed optical sensor allows full-field geometry acquisition and precise feature measurement to take place within one automated workflow.
Integrated hardware and optical sensing
The metrology robot ZEISS TALOS MR and the compact blue-light sensor ZEISS TALOS AX form an integrated measurement unit. ZEISS also pairs the unit with the metrology-grade ZEISS TALOS RT rotation table and the ZEISS TALOS Safeguard safety concept. According to Dr. Jan Thesing, head of ZEISS’s 3D Optical Systems business unit, TALOS represents a shift in automated metrology by integrating metrological capabilities directly into the system while retaining the speed, range and flexibility of robotic kinematics.
ZEISS describes the TALOS AX sensor as addressing a longstanding optical-metrology challenge: combining fast surface measurement with precise feature measurement. The sensor uses two 24-megapixel cameras and captures images at 100 Hz, or up to 200 Hz in a fast-scan mode. It has a 500 mm wide measurement volume and four multidirectional feature flashes. According to the company, these capabilities allow it to measure large surfaces for geometry analysis and digital twins as well as features such as holes, edges, bolts and threads.
Production-oriented programming and analysis
The robot and system concept are designed to withstand common production-environment influences, including temperature variation, vibration and dust. Measurement tasks can be prepared offline from a CAD model, and 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 inspection tasks. One-click programming, efficient robot motion and a streamlined setup are intended to raise throughput and make better use of measurement capacity.
With ZEISS INSPECT, users can carry out complete analyses, generate reports and integrate measurement results into existing processes. The system is intended for use both near production and in dedicated measurement rooms.
Target applications
ZEISS TALOS is aimed at automotive, aerospace and commercial vehicle manufacturing. Applications cited by the company include car bodies, hang-on parts and giga-casting parts, as well as aerostructures, jet engines, truck cabins and weld seams. High-resolution measurement data is intended to help evaluate component quality and deviations. Virtual tools can be used to assess functional dimensions, gap sizes and flushness, for example in automotive assembly.