ZEISS Research & Quality Solutions (ZEISS RQS) has introduced ZEISS TALOS, a metrology robot built for automated, high-volume inspection. The system pairs metrology-grade accuracy with flexible robotic kinematics and, according to the company, delivers measurement uncertainty below 100 µm across a reach of 3.30 meters. ZEISS positions TALOS for measuring medium-sized and large components, including areas that are difficult to access with conventional line-of-sight measurement systems.
Positioning is handled by the robot itself. ZEISS says the arm places the sensor precisely and repeatably without external tracking systems or reference markers, which the company links to reliable measurement of medium-sized and large parts. A newly developed optical sensor covers both full-field geometry acquisition and precise feature measurement within a single automated workflow, so surface capture and feature checks no longer require separate setups.
Robot, sensor, rotation table and safety concept
The metrology robot ZEISS TALOS MR and the compact blue-light sensor ZEISS TALOS AX form an integrated measurement unit, complemented by the metrology-grade ZEISS TALOS RT rotation table and the ZEISS TALOS Safeguard safety concept. Dr. Jan Thesing, Head of Business Unit 3D Optical Systems at ZEISS, framed the launch as a structural change for the category: metrological capabilities are integrated directly into the system, he said, while the speed, range and flexibility of robotic kinematics are retained.
One sensor for surfaces and features
Combining fast surface measurement with precise feature measurement has long been a challenge in optical metrology. ZEISS TALOS AX carries two 24-megapixel cameras that capture images at 100 Hz, or up to 200 Hz in fast scan mode. A 500 mm wide measurement volume and four multidirectional feature flashes let a single sensor cover large surfaces for geometry analysis and digital twins as well as defined features such as holes, edges, bolts and threads.
Designed for production use
The robot and system concept are built to withstand typical environmental influences including temperature variation, vibration and dust. Measurement tasks can be prepared offline on the basis of the CAD model, after which ZEISS INSPECT automatically calculates the required measurement positions and robot paths; ZEISS says this significantly reduces the time and effort needed to plan new tasks. One-click programming, efficient robot motion and a streamlined setup are intended to raise throughput and make more efficient use of measurement capacity. Through ZEISS INSPECT, users can also run complete analyses, generate reports and integrate measurement results into existing processes.
Target industries and applications
ZEISS TALOS is designed for automotive, aerospace and commercial vehicle manufacturing, both near production and in dedicated measurement rooms. Supported applications range from car bodies, hang-on parts and giga-casting components to aerostructures, jet engines, truck cabins and weld seams. High-resolution measurement data allows precise evaluation of component quality and deviations, and virtual tools can be used to assess functional dimensions, gap sizes and flushness, for example in automotive assembly.