ZEISS today announced the launch of the OMNIA GC 220-180, a groundbreaking 2D X-ray inspection system meticulously engineered to meet the stringent demands of modern high-volume production in the automotive industry. This fully automated solution empowers manufacturers to conduct high-precision inspections of large-format aluminum castings, such as battery trays and front and rear underbody structural components, seamlessly within inline or atline operations.
The ZEISS OMNIA GC 220-180 redefines X-ray inspection through its innovative use of high-precision Cartesian manipulators. Unlike traditional articulated robots hampered by rotary joints, these Cartesian axes deliver smooth, linear motion, enabling exact tilting, zooming, and positioning. This advanced capability grants the machine unparalleled access to even the most intricate sections of complex castings, ensuring comprehensive inspection coverage. With an X-ray beam capable of a ±60° tilt and impressive travel speeds up to 15 m/min, the ZEISS OMNIA GC facilitates rapid, flexible, and collision-free inspections from virtually any angle.
Its modular architecture, available in single- or double-door versions, allows for seamless adaptation to diverse production setups. The combination of Cartesian kinematics, dual tilts of both the X-ray tube and detector, and an adjustable focus-detector distance (FDD) between the tube and flat-panel detector makes it possible to thoroughly examine component areas that were previously challenging to reach.
A key feature of the ZEISS OMNIA GC is its advanced Automatic Defect Recognition (ADR). Powered by the in-house developed FARIS software, the system provides fully automated inspection and defect evaluation in compliance with ASTM standards. This intelligent functionality enables the system to automatically detect and sort defective parts, significantly enhancing quality control processes. FARIS also includes integrated ASTM evaluation and classification, image optimization, and defect simulation.
"With OMNIA GC 220-180, ZEISS is setting new standards in the automated X-ray inspection of large aluminum castings," stated a ZEISS spokesperson. The system boasts an impressive inspection volume of up to 2200 × 1800 × 900 mm while maintaining a relatively compact footprint of only 5 m × 2.7 m. Crucially for high-volume production, it achieves remarkable cycle times of just 3 – 3.5 seconds per view, although the exact duration can vary based on factors like position sequence, exposure time, and part geometry complexity.
Furthermore, the ZEISS OMNIA GC prioritizes user experience with its intuitive operation. CNC-supported programming is quick and easy via a user-friendly graphical interface, eliminating the need for a teach pendant. An anti-crash simulation further speeds up programming setup and completely eliminates the risk of collision, while real-time monitoring and diagnostic functions bolster process reliability.
The ZEISS OMNIA GC 220-180 stands as a testament to ZEISS's commitment to combining state-of-the-art hardware with sophisticated in-house developed software, offering an optimal solution for the non-destructive testing of large, complex structures in the automotive sector.
Reference: https://metrology.news/zeiss-launch-large-scale-automated-x-ray-inspection/
