As the global energy industry increasingly shifts towards sustainable and renewable sources, the demand for efficient and reliable power generation equipment, such as hydraulic turbines, continues to grow. In this context, the precision of critical components like the spiral casing is essential. Even minor dimensional deviations in the casing can lead to misalignments, reduced efficiency, and operational failures.
Traditional measurement methods often fall short in accurately capturing the complex geometry and large scale of these components. 3D scanning technology provides a precise, real-time, non-contact solution, enabling manufacturers to accurately capture the full dimensions of the spiral casing.
Client Overview
The client is a leading manufacturer of hydraulic turbines, specializing in the production of high-efficiency turbine systems for the global hydropower industry. They design and produce a wide range of turbine types and associated equipment, including spiral casings, critical for the turbine's performance.
Given the complexity and large size of the spiral casings, the client needed a high-precision inspection solution to ensure dimensional accuracy, avoid assembly issues, and meet strict industry standards.
these needs, the client required a solution that could: Measure large, complex geometries accurately. Detect, address, and prevent deformations or misalignments to ensure proper fit during assembly. Provide real-time feedback for continuous quality control and adjustments.
Solution: 3D Scanning for Spiral Casing Inspection
To overcome the limitations of traditional measurement methods, the client implemented TrackScan Sharp 3D scanning system, designed for large-volume, high-precision measurements, provided an effective solution for inspecting the spiral casing with several key advantages:
Portable and Reliable On-Site Scanning
The TrackScan Sharp was ideal for on-site measurement of the spiral casing, which due to its size. The system’s portability allowed the client to conduct precise measurements directly in the workshop, improving operational efficiency.
ensured stable performance even in challenging workshop environments, unaffected by vibrations, temperature changes, or noise.
Highly-Efficient Measurement
on-board processor for edge computing, the 3D scanning system’s tracker output 3D coordinates in real time after processing images. It sped up the data transfer and the measurement process.
Besides, its one-position measurement range is larger than that of traditional measurement method. With a few repositioning, it can efficiently capture the data of large-scale parts and ensure the precision by reducing the times of data alignment. Combined with its high scanning rate, the measurement was completed in just 2 hours.
Precise Data Capture
TrackScan Sharp enabled capture of the complete geometry of the spiral casing, including complex curvesintricate features.
The advanced algorithms ensured accurate measurement of dimensions and machining allowances. This 3D scanning system allowed the client to obtain precise data and ensured the parts manufactured are of high standards.
Detailed Deviation Analysis
The scanning data was processed to create a detailed 3D model of the spiral casing, which was then compared to the original CAD model. This deviation analysis helped identify discrepancies and provided critical insights for quality control.
The deviation color map allowed the client to identify dimensional deviations promptly, so that they minimized defects and ensured the casing met strict tolerances throughout the manufacturing process. It also highlighted specific machining allowances on the surfaces to be machined, ensuring precise machining. Additionally, the high-precision data, especially precise hole diameters, provided a valuable reference for subsequent assembly.
The implementation of the TrackScan Sharp 3D scanning system successfully addressed the client's challenges, providing a comprehensive and precise solution that significantly improved the accuracy, efficiency, and reliability of the inspection process for the spiral casing. Click here to know more.
