ZEISS Research & Quality Solutions (ZEISS RQS) has introduced ZEISS TALOS, a robot-based optical metrology system intended for automated, high-volume inspection. The company says the system combines metrology-grade accuracy with the reach and flexibility of robotic kinematics, targeting medium and large components that can be difficult to measure with conventional line-of-sight systems.
ZEISS specifies measurement uncertainty below 100 µm over a reach of 3.30 meters. The robot positions the sensor without external tracking systems or reference markers, a design intended to make measurements precise and repeatable while allowing access to areas that line-of-sight systems may not reach. A newly developed optical sensor supports full-field geometry acquisition and precise feature measurement within one automated workflow, according to the company.
Integrated hardware and safety concept
The system includes the ZEISS TALOS MR metrology robot and the compact blue-light ZEISS TALOS AX sensor as an integrated measurement unit. It is complemented by the ZEISS TALOS RT rotation table and the ZEISS TALOS Safeguard safety concept. Dr. Jan Thesing, Head of Business Unit 3D Optical Systems at ZEISS, described the launch as a shift in automated metrology: metrological capabilities are integrated directly into the system while the speed, range and flexibility of robotic kinematics are retained, he said.
One sensor for surfaces and features
ZEISS says optical metrology has long faced a trade-off between fast surface measurement and 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. Its measurement volume is 500 mm wide, and four multidirectional feature flashes support measurement of large surfaces for geometry analysis and digital twins as well as features such as holes, edges, bolts and threads.
Designed for production environments
The robot and system concept are designed to withstand temperature variations, vibration and dust, conditions typical of production settings. Measurement tasks can be prepared offline from a CAD model, while ZEISS INSPECT software automatically calculates the required measurement positions and robot paths. ZEISS says this reduces the time and effort needed to plan new tasks. One-click programming, efficient robot motion and streamlined setup are intended to raise throughput and make better use of measurement capacity. ZEISS INSPECT also supports complete analyses, report generation and integration of measurement results into existing processes.
Target applications
ZEISS TALOS is intended for automotive, aerospace and commercial vehicle manufacturing, both near production lines and in dedicated measurement rooms. Applications include car bodies, hang-on parts, giga-casting parts, aerostructures, jet engines, truck cabins and weld seams. High-resolution measurement data is used to evaluate component quality and deviations, while virtual tools can assess functional dimensions, gap sizes and flushness, for example in automotive assembly.