Application of Industrial-Grade High-Precision 3D Scanners in the Development of New Product Inspection for Casting Dimensions
The product is scanned in three dimensions using a high-precision 3D scanner, and the resulting point cloud data is transferred to a computer for analysis. During the scanning process, various parameters such as device configuration can be adjusted to enhance scanning accuracy. The higher the precision, the more detailed the point cloud becomes. Once the data is collected, a digital model is created from the point cloud and compared with the original product design model. This process is illustrated below:
After aligning the model number with the actual product number, the product is compared against both 3D and 2D dimensions. The 3D dimension comparison includes color deviation mapping, 3D dimensioning, and geometric tolerance checks. For 2D comparisons, any section of the product can be selected to measure feature distances, radii, and angles. This helps ensure that all critical dimensions meet the required specifications.
Once all necessary 3D dimensional inspections and annotations are completed, detailed inspection reports can be generated. If multiple units of the same product need to be tested, previous test results can serve as a template. Simply replace the original scan data with new data and run an automated report generation to produce updated inspection reports based on the latest scans.
Industrial Application of High-Precision 3D Scanners for Detecting New Sizes of Casting Products
During the development of new casting products, checking casting dimensions is a crucial and essential step. Traditionally, manual scribing was used to inspect castings, but this method is limited in measuring complex or curved surfaces. Moreover, many modern products only provide 3D data without 2D drawings, making traditional measurement methods less effective. As a result, the use of 3D scanning has become increasingly popular due to its efficiency and accuracy.
1) Casting Inspection
The scan data of the casting and the 3D numerical model are imported into analysis software. Alignment is typically done by referencing key features. First, the cylinder's horizontal machining positioning points are used as a reference for fitting. Then, the alignment is automatically completed. The choice of alignment method and reference depends on the specific product. It is recommended to use the primary machining positioning points for better accuracy. The principle is shown in the figure below:
After alignment, a 3D comparison is performed to generate a color deviation map. By analyzing the color differences on the surface of the casting, engineers can easily identify dimensional deviations and quickly determine where adjustments may be needed. Specific comments can also be added to highlight areas with significant deviations. This helps assess whether there is sufficient machining allowance and check for flatness or positional tolerances. Large deviations can be annotated for further review and analysis.
Key dimensions such as the barrel diameter and center-to-center distance between cylinders can be measured efficiently using feature creation and 3D dimensioning tools.
2) Sand Core Inspection
In the development of new casting products, the size of sand cores can change over time due to factors like deformation or wear from the core box. Historically, it was challenging to accurately measure sand core sizes, which made it difficult to track their condition. However, the use of non-contact 3D scanning allows for precise and efficient measurement of sand core dimensions.
During rapid trial production, many sand cores are produced without molds, leading to variations in size. Multiple tests are often required to ensure the core meets the desired specifications. Based on the test results, adjustments can be made to correct any oversized or undersized sections of the core.
Application of industrial-grade high-precision 3D scanners in the development of new product detection for casting size
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