A motor manufacturer intends to conduct reverse modeling based on existing mature rotor products for product modification design and localized alternative development. It is necessary to quickly obtain a complete 3D digital model of the rotor while ensuring accuracy. The customer uses Holon 3D handheld industrial scanners combined with reverse engineering software to complete the digital conversion from physical objects to 3D models, cutting the modeling cycle by more than 60%.

Physical picture

The rotor is a cylindrical rotating structure as a whole, and the surface of the magnetic pole is an irregular curved surface. Calipers and height gauges can only measure a small number of exposed linear dimensions. The curved profile, gaps and symmetrical structures cannot be accurately surveyed and mapped, resulting in large deviations between the built model and the physical object. Manual surveying and mapping of the entire rotor using traditional measuring tools takes at least 3 to 5 days for complete modeling. Cumulative errors arise from manual readings and hand-drawn profiles. Subsequent trial runs of stamping and turning molds require repeated rework, which greatly extends the new product development cycle and makes it difficult to meet customer requirements.

Physical picture

The Holon high-precision blue light 3D scanner is selected, and the device is perfectly adapted to the non-destructive reverse engineering scenario of generator rotors. Adopting non-contact optical scanning with an ultra-high scanning accuracy of 0.02 mm, it can fully restore details including shaft tolerances, claw pole curved surfaces and annular structures of slip rings. Complete point cloud data can be quickly generated in only 10 minutes, with the efficiency increased by more than 10 times compared with traditional surveying and mapping methods. Geomagic Studio reverse engineering software is used for point cloud processing and surface reconstruction, and the results are finally imported into CAD software such as Pro/E and UG for solid modeling. The 3D scanning and reverse modeling solution from Holon provides an efficient path from physical object to digital model for automotive generator rotors. It effectively addresses pain points such as difficult surveying and mapping, long cycles and insufficient accuracy of complex rotating parts, helping enterprises shorten product development cycles and accelerate the pace of domestic substitution.

STL image of scanned data

Reverse modeling STP drawing