POWER GENERATION 3D MEASUREMENT SOLUTIONS
The power generation industry has not been spared from the ever-increasing need to be globally competitive. Pressure to produce parts of higher and higher quality while simultaneously cutting costs never ceases.
In addition to the high technology involved in turbine production, new requirements can make inspection difficult. Standard measurement tools can no longer be used because they are either time consuming or lack efficiency.
To solve their ever-changing needs, professionals in this industry rely on NUB3D scanners, whether for reverse engineering of turbines or for quality control.
To manufacture blades at the lowest possible cost through design optimization.
The simulations and CFD & FEA analysis required to adapt the turbine design to tolerance are usually based on the part’s original CAD file instead of on the geometry of the actual part.
With SIDIO 3D scanners, the product can be scanned at every stage of development as required. Scan data provides the full geometry of the actual part. This information can be easily shared among different departments, such as Quality, Engineering and the designers.
Drawings are simplified because with a full surface database, they don’t have to be as detailed as they were previously.
Only a few important functional dimensions need to be defined, and for all other surfaces either CAD data is set as master or a profile tolerance is set.
Additionally, tolerances can be relaxed for non-critical areas, whereas previously, the entire surface had the same drawing tolerance specification.
To repair or manufacture replacements for old turbines or blades, or for those that have been transferred.
This is a huge challenge when the original drawings or CAD data have been lost or misplaced.
Moreover, engine component production tooling undergoes modifications during the life of the model engine. Therefore, even the original CAD data may not match current design.
Measuring such parts using CMMs to obtain their geometry is very time consuming.
A SIDIO optical digitizing system allows you to scan objects of almost any size quickly and precisely. Results of very high resolution are obtained, which means you can see even the finest details, such as the leading and trailing edge of blades.
Scanned data can be imported into common CAD systems for surface reconstruction.
Design changes can be made to these surfaces at a later stage.
The overall process time to reconstruct a blade is reduced. Improvements can be made to the design and additional stability and flow simulations can be carried out using scanned data.
To reduce machining time by determining a forged product’s material stock amount and location when a third party has delivered it.
Create a 3D scan of the forged part with a SIDIO sensor and compare it to the nominal CAD data of the blade.
Fit scanned data onto the nominal 3D CAD data using a best-fit alignment.
After comparing if the scanned data is aligned to the CAD data, you can define where there is either extra or missing material. This way, you can adapt your machining process, referred to as CAM routines.
Machining time is minimized because the CNC tool only works where stock material has been found, thus avoiding working where no material exists.
To reduce production development time and improve competitiveness.
Measuring the geometry of the product is required in almost every step of production and in each iteration stage (ceramic cores, wax models, injection molds, etc.).
Today, traditional methods of inspection using CMMs are too slow. Moreover, the increasing complexity of airfoils, nozzles and impellers requires new measurement and inspection methods.
Using SIDIO scanners, parts can be measured quickly and easily to obtain the full measurement. This makes determining measurement points prior to taking the measurement unnecessary.
Deviations in the geometry are visualized in insightful color maps that are easy to understand. There is no need for many pages of spreadsheets with numbers that are difficult to figure out.
By analyzing each step in the production process, production problems can be identified and actions can be taken to ensure that no defective parts are being produced.
Manufacturers are able to reduce spending on inspection and speed up development. Having a full surface database at your disposal allows for flexible analysis without the need for new measurements.
To meet increasing production quality requirements, such as more measuring points and flexible measuring solutions.
Blades are highly sophisticated products that may also be relevant in terms of safety. Therefore, ensuring that the customer doesn’t receive any defective parts is essential.
An automated solution based on the SIDIO AIRUS robotized sensor or a simpler configuration of a standard SIDIO scanner combined with an automated rotary table allows for 100% inspection of the parts produced.
Automatic macros provide the ability to measure airfoil contours, leading and trailing edges and root and tip geometry, and ultimately show the pass/fail result in a color map report.
Generally, part inspection time is shortened, therefore increasing throughput within quality departments.
At the same time, a more complete inspection can be carried out so users can identify problems in unexpected areas, trends in part shrinkage, airfoil twist and mold wear.