Hexagon’s Manufacturing Intelligence division has introduced a new technology aimed at reducing quality inspection delays in large-scale manufacturing. This system combines laser tracking with laser radar functionality, allowing manufacturers to measure detailed features and meet precise assembly tolerances from tens of meters away. Built on established measurement and positioning technology, the Leica Absolute Tracker ATS800 significantly enhances productivity by safely and efficiently measuring critical features, helping to alleviate common production bottlenecks.
The new system offers manufacturers the ability to accurately measure fine edges and features over large distances, providing exceptional productivity in measurement processes from a convenient distance. Whether used for inspecting aerospace structures, automotive components, ship sections, or wind turbine parts, there’s no need for operators or robots to be near the part being measured. This reduces the risk of unreliable measurements, improves safety, and saves time.
By combining direct scanning with reflector tracking, the system replaces two devices with one. With Hexagon’s patented PowerLock technology, the ATS800 automatically locks onto a fixed reflector and tracks it in real-time, providing an absolute position reference. This capability greatly simplifies robotic automation by offering precise position referencing within a broader coordinate system, whether the tracker is mounted on a linear rail or an autonomous mobile robot (AMR).
The ATS800 is a versatile tool for high-precision measurement of intricate geometries and complex surfaces from a safe distance, making it suitable for rapid inspection in various industries:
- Aircraft fuselages can be quickly inspected during production without needing to position reflectors, cutting total inspection time from hours to minutes. Multiple devices or AMRs can inspect several fuselage sections overnight, minimizing shift disruption.
- Guided assembly processes that rely on real-time digital measurements will benefit from the ATS800’s simultaneous tracking, providing precise alignment guidance during 3D assembly without the need to stop for recalibration.
- Its fast, accurate measurement of holes, fastenings, and edges can keep up with high-volume automotive production, automatically inspecting critical features within seconds without interruptions or the risk of robot collisions.
- Inaccessible features, such as bolt pattern holes for wind turbine sections or industrial pipework, can be safely and reliably measured on the factory floor.
Robotic automation has traditionally been limited by cabling and large control systems, complicating the use of AMRs and robot deployment in large-scale manufacturing. However, the ATS800 with an IP54 rating aims to change that through its wireless operation while being highly portable, with all systems integrated into a single lightweight tracker and a small control box that can be easily mounted and integrated with common robotic systems.
Based on Hexagon’s established Absolute Tracker platform, the ATS800 expands the successful ATS family, joining the existing ATS600. Customers can interchange accessories like batteries, tripods, and reflectors as needed, ensuring compatibility with their existing systems. Designed to integrate smoothly into existing workflows, the ATS family supports Hexagon’s software development kits, providing open support for both manual and automated third-party solutions.
Representatives from Hexagon also chimed in and provided more insights regarding the respective industries, trends, and the ATS800 itself.
“Industries like aerospace and shipbuilding are making large structures where scale and detail are equally important. We’re excited to offer manufacturers a system that delivers leading-edge capabilities to measure intricate features withl ess disruption at the heart of production and throughout the critical stages of assembly.” – Pirmin Bitzi, General Manager for Portable Measuring Devices at Hexagon
“This laser tracker is a testament to our commitment to work with our customers very closely and develop products that address core market needs. Complementing our laser scanning systems, the highly portable ATS800 can cut manual processes from hours to minutes and support the generation of a digital twin. Moreover, it can be used on our customers’ preferred AMR or robot systems to fast-track ‘push button’ automated inspection with confidence across the shopfloor.” – Andreas Werner, CTO of Manufacturing Intelligence division at Hexagon
The Leica Absolute Tracker ATS800 will be available to global customers in 2025. For more details, visit https://go.manufacturing.hexagon.com/ats800-imts/.
