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 non-contact large-part measurement – sufficient to perform detailed feature and edge inspections and meet tight assembly tolerances from tens of meters away. The Leica Absolute Tracker ATS800 offers manufacturers significantly improved productivity in large-scale part manufacturing and assembly, where its reflector tracking and high-accuracy direct scanning are combined to rapidly and reliably measure critical features and minimize production bottlenecks on the shop floor.

This new technological development will allow manufacturers to accurately measure fine edges and features across large volumes with unparalleled measurement process productivity, and at a safe and convenient standoff distance. Whether for large aerospace or automotive structures, ship sections or wind turbine components, when using the ATS800 there is no need for operators or robots to be in close proximity to the part being measured. This avoids 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 and immediately “locks on” to a reflector and tracks its movements in real-time, providing an absolute reference. The ability to measure target reflectors also greatly 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 high-precision 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 unique 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 the alignment and fastening of huge wind power sections, or similar industrial or construction pipework in the factory.
• Pirmin Bitzi, General Manager for Portable Measuring Devices at Hexagon, commented: “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, added: “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 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. I am 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 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 hugely 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.

The new Leica Absolute Tracker ATS800 will be available to all customers in 2025.

In advance of the official launch, find out more at Chicago’s IMTS exhibition this week. On-site, Hexagon’s Manufacturing Intelligence division will give industry insiders a first look at their next big development in laser tracker technology, available to all customers in 2025

Hexagon is the global leader in digital reality solutions, combining sensor, software and autonomous technologies. We are putting data to work to boost efficiency, productivity, quality and safety across industrial, manufacturing, infrastructure, public sector, and mobility applications. Our technologies are shaping production and people related ecosystems to become increasingly connected and autonomous – ensuring a scalable, sustainable future. Hexagon has approximately 24,500 employees in 50 countries and net sales of approximately 5.4bn EUR. Learn more at hexagon.com and follow us @HexagonAB.