Birr Machines AG, based in Kleindöttingen, Switzerland, is a service provider for 50 kW and 30 MW electrical equipment. In addition to equipment development, the company offers after-sales service for machines from all over the world that were manufactured 55 years ago by ABB (formerly BBC).
Last year, the company was commissioned to replicate an 8.5 MW integrated stator in the nuclear field. The challenge was to accurately reproduce the steel structure of the part, despite the lack of documentation.
In order to carry out this task efficiently and achieve the desired quality, the metrology service provider SCAN IT 3D GmbH was entrusted with the task of drawing up a situation survey and creating a 3D model with defined dimensions.
For 3D scanning, Creaform's MetraSCAN 3D was chosen. This scanner is particularly suitable for 3D measurement of large mechanical objects, such as electric motors. The MetraSCAN 3D scans quickly, with high accuracy and high resolution. In this particular case, an electric motor of about 2x2x2.5 meters was digitized. About 35 square meters were captured with the MetraSCAN 3D. Individual measurements, in locations that were not accessible to the scanner, were performed by the HandyPROBE probing system and then combined with scanner data.
The fiberglass covers screwed to the end of the coils could also be measured separately without disassembling them.
The customer used the SolidWorks CAD program for further data processing. This makes it possible to superimpose the data from the 3D scan on the CAD model to be reproduced and thus offers very little room for interpretation errors. Reverse engineering data can be passed using Feature Tree and all measurements from Geomagic Design X to SolidWorks, further simplifying the entire workflow.
Geomagic Design X software was used to reverse engineer the steel structure. The data was transferred to Birr Machines AG as native SolidWorks models. The caches were also created in Design X and could be taken over directly for production.
For this project, SCAN IT 3D GmbH used reverse engineering to create a design very close to the scan data, at the customer's specific request. This provided a solid basis for further processing in the customer's CAD system.
Results: 1 day of scanning and 2 days of reverse engineering
The realization of the 3D scanning using the MetraSCAN 3D took one day. Reverse engineering of the turbine housing and caches was completed after 2 days. Added to this are the coordination with the customer and some minor corrections. A duration of 3 to 5 days can therefore be considered very realistic for such a project.
Benefits for the customer
No action had to be taken by hand
No additional measuring tools had to be purchased
All dimensions were quickly available to scale, in the CAD software.
Thanks to colorimetry comparisons, the scanned model can always be compared with CAD data.
SCAN IT 3D GmbH has already carried out many successful projects thanks to Creaform's 3D scanners and reverse engineering know-how. This made it possible to repair old installations and systems quickly and in accordance with customer expectations.
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