Hexagon Brings Metrology Technology into Industrial Automation Systems
Large-scale manufacturing is entering a new stage where industrial automation, robotics, and precision measurement must work together. Hexagon’s Manufacturing Intelligence business area has introduced OPC UA support for SpatialAnalyser, its software platform for large-volume metrology and alignment applications.
The new integration connects high-accuracy laser measurement systems with industrial control systems, including PLC platforms, robotic controllers, and factory automation networks. As a result, manufacturers can improve robotic accuracy when producing large and complex components.
Industries such as aerospace, energy, shipbuilding, and heavy equipment manufacturing increasingly require higher production efficiency without reducing quality. However, traditional robotic automation often faces limitations when manufacturers need micron-level positioning accuracy on large assemblies.
OPC UA Enables Smarter Communication Between Robots and Control Systems
The introduction of OPC UA support allows SpatialAnalyser to communicate directly with industrial control environments. OPC UA has become a widely adopted industrial communication standard because it enables secure data exchange between PLCs, DCS platforms, robots, and other automation devices.
In modern factory automation systems, robots provide speed and flexibility, but they cannot always maintain the required precision during large-scale operations. Factors such as mechanical deformation, thermal expansion, and installation errors can affect positioning accuracy.
Therefore, manufacturers increasingly combine robotic systems with metrology solutions. By integrating measurement feedback into automation workflows, production lines can automatically correct alignment errors and maintain consistent manufacturing quality.
From an industrial automation perspective, this approach represents a shift from traditional fixed-position robotics toward measurement-driven manufacturing.
SpatialAnalyser Improves Metrology-Assisted Manufacturing Processes
Hexagon designed SpatialAnalyser as a software solution for managing complex measurement and alignment operations. The platform supports industrial applications where manufacturers need accurate inspection data before, during, and after assembly processes.
The latest release adds OPC UA client capabilities with encryption and authentication features. These functions help protect communication between metrology equipment and industrial control systems.
Moreover, Hexagon provides 25 new MP/SDK commands for developers. These commands allow system integrators to create customized OPC UA automation workflows for robotic production environments.
According to industrial automation experience, software-level integration often determines whether advanced measurement technologies can achieve practical value on production floors. A high-precision sensor alone cannot improve manufacturing efficiency unless it connects effectively with PLC, robot, and MES systems.
Robot Calibration Technology Improves Large-Part Manufacturing Accuracy
Alongside the SpatialAnalyser update, Hexagon has introduced SARCA, a robot calibration device designed for high-accuracy industrial robot applications.
SARCA uses multi-zone and multi-tool calibration methods to improve robot positioning performance. Hexagon states that the technology can increase industrial robot accuracy by up to ten times in suitable applications.
For large aerospace structures, ship components, and energy equipment, robot calibration plays an important role. A small positioning error can become significant when a robot operates across several meters of workspace.
In practical factory automation projects, engineers often need to combine robot calibration, laser tracking, and PLC-based control logic. This combination helps create closed-loop manufacturing processes where measurement data guides automated corrections.
Leica Absolute Tracker ATS800 Expands Precision Measurement Capabilities
Hexagon has also expanded SpatialAnalyser support for the Leica Absolute Tracker ATS800. This metrology device provides multiple measurement functions, including room scanning, reflector-based laser tracking, and direct feature scanning.
The ATS800 enables manufacturers to inspect large components without relying only on traditional measurement setups. Through Hexagon’s System Integrator Programme, OEMs and automation partners can include new metrology technologies in customized production solutions.
This development reflects a broader trend in industrial automation. Manufacturers are moving from isolated inspection stations toward integrated quality control systems connected with factory automation networks.
Aerospace Manufacturing Demand Drives Industrial Automation Development
The aerospace sector demonstrates the growing need for precision automation. Aircraft manufacturers continue to manage significant production requirements, creating pressure for faster assembly processes and improved manufacturing consistency.
Large aircraft structures involve thousands of complex alignment points. Manual measurement methods often require significant labor and time. Therefore, automation technologies that combine robotics, metrology, and digital control systems can help manufacturers increase throughput.
However, industrial automation engineers must carefully evaluate system architecture. Successful implementation requires coordination between PLC programming, robotic control, measurement software, and production management systems.
Industry Perspective: The Future of Measurement-Driven Automation
From an industrial automation engineering perspective, Hexagon’s OPC UA integration highlights an important industry direction: manufacturing systems are becoming more connected and data-driven.
Traditional automation focused mainly on machine control through PLC and DCS platforms. Modern factories increasingly require real-time feedback from sensors, robots, inspection systems, and digital platforms.
OPC UA provides a standardized communication foundation for these connected environments. When combined with precision metrology, it allows manufacturers to build smarter production systems that can adapt to real-world conditions.
However, companies should consider implementation factors such as network architecture, cybersecurity requirements, integration costs, and operator training before deploying advanced automation solutions.
Industrial Applications and Solution Scenarios
Aerospace Component Assembly Automation
Aircraft manufacturers can use SpatialAnalyser with robotic systems to improve drilling, positioning, and alignment processes for large structural components.
A typical solution includes:
- Industrial robots for automated machining or assembly
- PLC systems for machine coordination
- OPC UA communication for data exchange
- Laser trackers for position measurement
- Metrology software for real-time correction
Shipbuilding and Heavy Equipment Manufacturing
Shipyards and heavy equipment manufacturers often work with oversized structures. Precision metrology combined with robotic automation helps maintain assembly accuracy across large production areas.
Engineers can use measurement feedback to adjust robotic operations and reduce manual rework.
Smart Factory Quality Control
Modern smart factories require continuous quality monitoring. By integrating metrology systems with factory automation platforms, manufacturers can create closed-loop inspection and production processes.
This approach supports higher efficiency while maintaining strict quality requirements.
Conclusion
Hexagon’s latest SpatialAnalyser release demonstrates how precision metrology is becoming a key component of industrial automation. By combining OPC UA communication, robot calibration, and advanced measurement technology, manufacturers can improve the accuracy of large-scale automated production.
As factories continue adopting PLC, DCS, robotics, and digital manufacturing technologies, measurement-driven automation will become an important foundation for future production systems.
For industrial automation companies, system integrators, and manufacturers, the challenge is no longer only automating machines. The next step is creating intelligent production environments where machines can measure, communicate, and continuously improve.