Case Study: 3D Scanning of Castings for Dimensional Inspection

Objective:

Implementation of Auto checking of Product’s dimensions and tolerances against the CAD design so as to rectify the final product via 3D Scanning Technology

Background / Current Work Process

• Manually set up the actual castings (size from 300mm to 4000mm, length, and width) and measure these castings.
• Manual measurements via measuring tapes, Vernier caliper, take a long time, about 2~3 days and measurement accuracy achievable is >300microns.
• Manual comparison of actual castings measurements VS CAD drawings to calculate the differences in tolerance and compile reports for next actions => 1-day job.
• The total time for the whole process is approximately 3~4 days.

Proposed Solution

1. Hardware: Shining 3D FreeScan X7+, Wireless 3D Laser Scanner
2. Software: Geomagic Control X

• X7+ is easy to set up, and measurements can be done simply by scanning the whole castings
• Good measurement accuracy: <100microns
• Significant time-saving in measurement: < 4hours
• Auto comparison of measurements vs CAD drawings via software reduces human errors
• Significant time-saving in comparison and report compilation can be within 30 mins

Benefits for Company

1. Improvement in Productivity by > 75%
   • Time take to measure castings and compilation of comparison reports will be reduced from 4 days to 1 day 
2. Improvement in Accuracy
   • Good measurement accuracy via X7+: <100microns
   • Reduce in human errors during manual measurements of products and compilation of reports
3. Digital Transformation
   • Automate manual processes to reduce “heavy reliance” inexperienced workers, so as to achieve the 1st step to Industry 4.0

Benefits for Workers

1. Upgrading of Skills
   • Workers get to learn new skills by using intelligent tools/equipment and software to simplify the current work process
2. Easier and Safer Work Process
   • Easier for workers to perform the job and lesser workers are needed to complete the same amount of workload
   • Reduction in human errors during manual measurements of products and compilation of reports
   • Less fatigue – in the past, a 2~3 days job can be completed within 4 hours.

Additional Information

1. The customer has 7 suppliers in China of which some are still using manual validation of products
2. The customer has referred their suppliers to contact Shining 3D