Zeiss has launched a metrology robot for automated, high-volume inspection of large aerospace components, from aerostructures to jet engines, that works without external tracking systems or reference markers.
Called Talos, the system combines metrology-grade accuracy with robotic flexibility, delivering measurement uncertainty below 100µm (micrometers) over a reach of 10.8ft (3.3m). It positions its sensor precisely and repeatably without external tracking, enabling measurement of medium-sized and large components, including areas that are hard to reach with conventional line-of-sight systems.
A newly developed optical sensor captures both full-field geometry and precise feature measurements in a single automated workflow, addressing a longstanding challenge in optical metrology of combining fast surface measurement with precise feature measurement.
The Talos AX blue-light sensor uses two 24-megapixel cameras capturing images at 100Hz, or up to 200Hz in fast-scan mode, with a 20in (500mm) measurement volume and four multidirectional feature flashes. That lets it measure both large surfaces, for geometry analysis and digital twins, and precise features such as holes, edges, bolts and threads.
Jan Thesing, head of the 3D optical systems business unit at ZEISS, said, “Talos marks a fundamental shift in the automated metrology category: metrological capabilities are integrated directly into the system, while the speed, range and flexibility of robotic kinematics are retained.”
The robot is built to withstand temperature changes, vibration and dust, near the production line or in a dedicated measurement room. Measurement tasks can be prepared offline from the CAD model, with Zeiss Inspect software calculating the required measurement positions and robot paths, cutting planning time and speeding throughput.
Zeiss said the system suits inspection of aerostructures, jet engines and weld seams, generating high-resolution data to evaluate component quality and deviations. It can also be used in other sectors, including automotive and commercial-vehicle manufacturing.
