ZEISS Research & Quality Solutions has introduced ZEISS TALOS, a metrology robot intended for automated, high-volume inspection. The system combines robotic kinematics with metrology-grade measurement, and ZEISS states a measurement uncertainty below 100 µm over a reach of 3.30 meters. The company says the robot positions its sensor precisely and repeatably without external tracking systems or reference markers.
That configuration is intended for medium-sized and large components, including areas that conventional line-of-sight measurement systems have difficulty reaching. A newly developed optical sensor supports both full-field geometry acquisition and precise feature measurement in a single automated workflow, according to ZEISS.
Integrated measurement unit
The ZEISS TALOS MR metrology robot and the compact blue-light ZEISS TALOS AX sensor form an integrated measurement unit. ZEISS also lists the metrology-grade ZEISS TALOS RT rotation table and the ZEISS TALOS Safeguard safety concept as part of the system. Dr. Jan Thesing, Head of Business Unit 3D Optical Systems at ZEISS, described the launch as a fundamental shift in automated metrology: in his view, metrological capabilities are integrated directly into the system while the speed, range and flexibility of robotic kinematics are retained.
Surface and feature measurement
Optical metrology has long faced the challenge of combining fast surface measurement with precise feature measurement. ZEISS TALOS AX uses two 24-megapixel cameras and captures images at 100 Hz, or up to 200 Hz in a fast-scan mode. A 500 mm wide measurement volume and four multidirectional feature flashes are intended to support both large-surface geometry analysis and digital twins, as well as precise features such as holes, edges, bolts and threads.
Production-oriented workflow
The robot and system concept are designed to withstand temperature variations, vibration and dust. Measurement tasks can be prepared offline from the CAD model, while ZEISS INSPECT calculates the required measurement positions and robot paths. ZEISS says this reduces the time and effort needed to plan new measurement tasks. One-click programming, efficient robot motion and streamlined setup are intended to raise throughput and make more efficient use of measurement capacity. ZEISS INSPECT also supports complete analyses, reports and integration of measurement results into existing processes.
Target applications
ZEISS TALOS is designed for automotive, aerospace and commercial vehicle manufacturing, both near production and in dedicated measurement rooms. The listed applications include car bodies, hang-on parts, giga-casting parts, aerostructures, jet engines, truck cabins and weld seams. According to ZEISS, high-resolution measurement data supports evaluation of component quality and deviations. Virtual tools can be used to assess functional dimensions, gap sizes and flushness, for example in automotive assembly.