Analyzing steam turbine components often requires capturing dimensional data from parts of arbitrary shapes and complex geometries, frequently located in hard-to-reach areas. Thanks to their exceptional portability, compact size, and ability to establish coordinate systems directly on the workpiece, Hualang 3D scanners enable data acquisition right on the turbine assembly—even when scanning inside the turbine casing.

Given that the quality of steam turbine components is critical to optimal performance, data acquisition must be precise and capture all information necessary for condition assessment or the creation of comprehensive 3D dimensional models. Hualang 3D scanners are the ideal solution for generating complete, accurate mesh models.

Compared to traditional measurement methods, HOLON 3D solutions offer significant time savings, enabling rapid measurement and analysis of dimensions and making the data immediately available to design engineers.

3D scanning of steam turbines
     

1. Based on client requirements, HOLON 3D engineers proposed a solution involving the use of the HOLON B71+ handheld 3D scanner and the HL-3DP 3D photogrammetry system to scan the steam turbine. This setup achieves a scanning speed of up to 2,020,000 measurements per second and a maximum accuracy of 0.01 mm, enabling the rapid and precise acquisition of comprehensive 3D data to serve as a reference for subsequent reverse modeling.

2. Using the 3D scan data, HOLON engineers employed Geomagic Design X reverse engineering software to create a 3D model of the steam turbine, facilitating efficient maintenance and remanufacturing processes.

3D scanning of the steam turbine casing       
       3D digitization is applicable across various fields and serves as a vital tool for enterprise design and manufacturing departments to enhance their development and production capabilities. When scanning a massive object like a steam turbine casing, traditional scanning methods are inefficient; they yield limited data and incomplete surface information, failing to meet the enterprise's rigorous standards for efficiency and quality. In contrast, while traditional photogrammetry-based scanners are slow—and often require time-consuming, labor-intensive powder coating—handheld 3D scanners leverage their inherent flexibility to rapidly scan large workpieces, offering high scanning speeds, ease of operation, and superior efficiency.

3D Scanning of Ultra-large Steam Turbines       
       Scanning the steam turbine casing—which involves two separate sections and a large surface area—presented challenges regarding cumulative scanning errors and seamless data stitching. To address these issues, HOLON 3D technical engineers proposed a solution: utilizing the α7000 large-format 3D scanner and the HL-3DP 3D photogrammetry system to rapidly acquire high-precision 3D data of the casing, and subsequently using reverse engineering software to convert the point cloud data into a triangular mesh model. This process provided robust data to support the design and manufacturing of the steam turbine's thermal insulation enclosure.

Gas Turbine 3D Scanning        
        

The inspection of gas turbine arc cross-sections utilizes the HOLON 3D HL-Scan online inspection system, which integrates state-of-the-art 3D scanning technology. This process eliminates the need for reference markers or powder spraying, offering a convenient "pick-up-and-scan" workflow; the handheld device allows for easy mobility, high-speed scanning, and superior precision, capturing high-accuracy 3D data rapidly. Additionally, the system can be integrated with robotic arms to minimize manual intervention, enabling automated inspection and boosting operational efficiency.

Once the data is imported into the 3D inspection software, users can quickly generate detailed inspection reports comparing the arc cross-sections against the original CAD model. This provides clear visibility into potential issues, enabling effective problem-solving for clients. By facilitating automated scanning and inspection, the system significantly enhances productivity, thereby shortening product R&D and manufacturing cycles while reducing production costs.

3D inspection of gas turbines       

To inspect the sealing integrity of steam turbine casing mating surfaces, the client utilized the HOLON3D handheld Model 49 scanner to assess deformation. Addressing the diversity of components and assembly alignment challenges, the scanner employs multiple scanning modes to ensure the completeness and accuracy of measurement data; the "Fine" mode captures even the minutest details, achieving a peak scanning precision of 0.01mm, while the "Wide-Range" mode rapidly acquires data (4,200,000 points/s) for large-scale components, significantly boosting measurement speed. The client was highly satisfied with the results. HOLON3D takes pride in technological innovation, demonstrating its capabilities through metrology-grade 3D scanners. We stand alongside our clients to forge a new chapter in intelligent industrial manufacturing.