Wireless 3D Scanning for Precise Dimensional Inspection of Casting Parts

[JuliaCao]

The sudden release of energy from a pressure vessel can cause catastrophic damage, which may endanger lives. Therefore, pressure vessels must be manufactured to precise specifications to ensure compliance with safety standards and regulatory requirements.

This case study explains how 3D scanning technology can enhance the quality control process for pressure vessels by enabling accurate inspection that helps manufacturers maintain high standards of production.

 

 

 

Essential Measurement for Pressure Vessel

Key measurements for assessing a pressure vessel's integrity include the welded beams, bolt hole position and diameter, and overall deviations. These measurements ensure the vessel's safety and compliance with design standards.

 

 

3D Scanning Process

The actual 3D scanning process involves the use of portable SIMSCAN 3D laser scanner, which captures the geometry of the pressure vessel by emitting laser that reflects off the surface. The 3D scanner collects a dense set of data points, creating a 3D point cloud. These data points represent the physical shape of the object.

 

 

Comparing the 3D Scan to the Solid Model

After the scanning process is complete, the next step is to compare the scanned data to the 3D Solid model of the pressure vessel. The Solid model is the digital representation of the pressure vessel as designed, with precise dimensions and tolerances specified.

 

 

Alignment and Surface Selection

To conduct an accurate comparison, it is essential to determine which reference surface on the pressure vessel will be used for alignment. Commonly, the external surfaces of the vessel are chosen. The scanner's data is then aligned with the corresponding surface on the SOLID model.

Surface alignment ensures that the scanned data corresponds directly to the design specifications. This comparison reveals any deviations in the physical vessel from its intended design, such as areas where the vessel is either too large or too small in relation to the specifications.

Deviation Analysis

Once the alignment is complete, the 3D scanned model and the SOLID model are overlaid. The software then generates a mesh comparison, showing the deviations between the two models. This is typically visualized using a color gradient scale, where each color represents a different degree of deviation.

Key Measurements

The quality of the welded seams has been carefully inspected to ensure there are no defects or weaknesses that could compromise the vessel's strength.

 

Additionally, stress concentration points on the inner surface have been detected, revealing areas where the reduction in the radius (R-angle) leads to an increase in stress levels. 

The flatness of the flange has also been measured, along with the dimensions and positioning of the holes, including their diameter, depth, and location accuracy. These measurements are critical in verifying that the pressure vessel meets design specifications and can safely withstand operational stresses.

 

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