(Hexagon: Waukesha, WI) -- Hexagon’s Manufacturing Intelligence division is previewing a newly developed laser tracker technology. Combining laser tracking with laser radar functionality, it brings traditional reflector-tracking accuracy to noncontact large-part measurement—sufficient to perform detailed feature and edge inspections and meet tight assembly tolerances from a distance.

The Leica Absolute Tracker ATS800 offers manufacturers significantly improved productivity in large-scale part manufacturing and assembly, where its reflector tracking and accurate direct scanning combine to rapidly and reliably measure critical features and minimize production bottlenecks on the shop floor. 

This new technological development will allow manufacturers to measure fine edges and features across large volumes, and at a safe and convenient standoff distance. Whether for large aerospace or automotive structures, ship sections, or wind turbine components, with ATS800 there’s no need for operators or robots to be in close proximity to the part being measured. This prevents unreliable measurements and safety issues while ensuring significant time savings.

By combining direct scanning and reflector-tracking capabilities, the new system replaces two pieces of hardware with a single device. Using Hexagon’s patented PowerLock technology, the ATS800 automatically  “locks on” to a reflector and tracks its movements in real time, providing an absolute reference. The ability to measure target reflectors also simplifies robotic automation processes by allowing precise positional referencing within a wider coordinate system when mounting the tracker on a linear rail or an autonomous mobile robot (AMR).

With its ability to perform precise measurements of intricate geometries and complex surfaces from a safe distance, the ATS800 will be a versatile measurement tool for rapid inspection in various industries and applications.

An aircraft fuselage can be quickly inspected alongside production without bringing target reflectors to the part, reducing total inspection time from hours to minutes. Using multiple devices or an AMR, several fuselage sections or panels can be batch-inspected overnight, further reducing inspection time and avoiding disruption during shifts.

Guided assembly processes use up-to-date digital measurements during 3D assembly and mating operations, and the ATS800’s simultaneous tracking capability provides metrology-grade guidance accuracy to help experts align and troubleshoot issues in real time without stopping to recalibrate and remeasure.

The accurate high-speed measurement of holes, fastenings, and edges can keep up with high-volume automotive production—automatically inspecting critical features within seconds without interruption or the risk of robot collision.

The new system can reliably measure inaccessible features, such as the holes that make up the bolt pattern for aligning and fastening huge wind-power sections or similar industrial pipework in the factory.

Pirmin Bitzi, general manager for portable measuring devices at Hexagon, says, “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 with less disruption at the critical stages of assembly at the heart of production.”

Andreas Werner, CTO at Hexagon’s Manufacturing Intelligence division, says, “This laser tracker is a testament to our commitment to work with our customers very closely and develop products addressing core market needs. Complementing our laser scanning systems, the 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 automated inspection with confidence across the shop floor. I’m pleased that we can offer our customers so much added value with these versatile application options.”

Until recently, robotic automation has been limited by the supporting cabling and large control cabinets that prevent AMR use and complicate robot deployment in large-scale manufacturing. The ATS800 is highly portable, IP54-rated, and can be operated completely wirelessly, integrating all systems and electronics into a single, lightweight tracker unit plus a small control box that can be securely mounted to and integrated with common robotics control systems.

This new technology is based on Hexagon’s established platform of Absolute Trackers, extending the successful ATS family that now includes both the existing ATS600 and the new ATS800. Customers will be able to interchange accessories like batteries, tripods, and reflectors as required across their existing install base as their needs change. Designed to plug into customer’s existing workflows, the device supports Hexagon’s comprehensive software development kits, providing open support for integration within third-party manual and automated solutions.

In advance of the official launch, find out more at the International Manufacturing Technology Show, Sept. 9–14, 2024, in Chicago at McCormick Place. Onsite, Hexagon’s Manufacturing Intelligence division will give industry insiders a first look at the new Leica Absolute Tracker ATS800, available to all customers in 2025. Learn more at hexagon.com.