ZEISS OMNIA GC 220-180

Next-gen automated inspection for large parts

ZEISS OMNIA GC 220-180 addresses the need for quality assurance of large-scale castings, offering a future-proof solution for defect detection in aluminum components. With an inspection volume of 2200×1800×900 mm and an automated workflow, the system enables 2D X-ray imaging in short cycle times and optimizes the entire production process across industries, whether in in-line or at-line operation.

Large-scale casting inspection in a small footprint
Fully automated defect detection & rejection
Scans even the most hard-to-reach features

The perfect system for defect detection in large-scale castings

Inspect parts as big as rear or front castings

ZEISS OMNIA GC is built for the future of automotive manufacturing, where larger castings demand more advanced inspection solutions. With its high-quality X-ray technology and precision-engineered system, it can handle even the largest components – delivering sharp, detailed imaging without compromising speed or accuracy. Its intelligent design provides full coverage in a single scan, reducing inspection time while maintaining high precision.

Single door or double door solutions for different requirements

ZEISS OMNIA GC can be configured as a single-door system for at-line or in-line inspection. With its compact footprint, it is ideal for sequential tasks with low to medium throughput while seamlessly integrating into existing production lines. Upgrading to a double-door system transforms it into a high-productivity in-line solution, enabling fast and automated part handling with parallel loading, unloading, and inspection of multiple pallets. This flexibility allows manufacturers to scale inspection based on production demands.

Cartesian axes for endless inspection angles

Our X-ray inspection system leverages high-precision cartesian manipulators to obtain images of all critical areas of a part. Unlike robotic solutions, which are restricted by rotational knuckles, Cartesian axes provide smooth, linear motion for precise tilting, zooming, and positioning. This allows the system to access even the most challenging areas of complex castings. With an X-ray beam offering an inspection tilt of ±60° and movement speeds of up to 15 meters per minute, ZEISS OMNIA GC ensures fast, flexible, and collision-free inspections from every possible angle.

Automatic Defect Recognition (ADR)

ZEISS OMNIA GC features advanced Automatic Defect Recognition (ADR) for fully automated inspection and defect evaluation in compliance with ASTM standards. The system automatically detects and sorts defective parts:

Identification of porosities, inclusions, cracks, shrinkages, and blowholes
Customizable defect libraries & built-in acceptability standards
Self-diagnostic features & calibration tools
Real-time production monitoring & defect statistics
Advanced image enhancements

Fast inspection cycle

The system delivers fast inspection cycles with precise cartesian movements and parallel loading/unloading for maximum efficiency. Unlike robotic solutions, it eliminates the need for safety reset positions, hence reducing delays. The intelligent system coordination further optimizes cycle times in both in-line and at-line operations, boosting throughput and productivity.
Maximized inspection area to footprint ratio

The monoblock design and cartesian mover principle achieve full inspection of large castings in minimal space. The shielded X-ray cabinet optimizes shopfloor use, while the internal pallet mover’s shifting and tilting maximize the usable inspection area within the smallest possible footprint. This design ensures efficient space utilization without compromising accessibility or performance.
Ready for full automation

ZEISS OMNIA GC is built for fast and reliable automation. Powered by the intuitive OMNIA CNC software with Automatic Defect Recognition (ADR), it enables automated defect evaluation to industry standards. Anti-crash simulation as well as software-based CNC cycle and automation control allow easy programming with minimal training, either remotely or via the control panel.
Upgradable & customizable

The system’s modular design allows smooth integration into existing production lines. Its adaptable architecture, e.g. single vs. double door, ensures future-proof scalability, enabling upgrades to meet evolving inspection needs. Whether adjusting to new workflows or expanding capabilities, the system’s flexibility makes it a long-term solution for dynamic manufacturing environments.
Full flexibility for inspection of various parts

The multi-fixture design allows different parts to be inspected using the same pallet, while the internal pallet mover provides maximum flexibility in part handling. Effortless adaptation to diverse components without changing setups enhances efficiency and reduces downtime.
Proven expertise & global support

Built on the best-in-class ZEISS BOSELLO OMNIA, ZEISS OMNIA GC benefits from decades of experience in casting inspection. With hundreds of systems installed worldwide and a service network spanning more than 40 countries, customers receive expert support wherever they operate. The system’s core components and motors align with other OMNIA models, ensuring easy maintenance and long-term serviceability.

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