How 3D Metrology Solutions Helped RMS install three new turbines

The installation of new turbines in an industrial setting is a complex process. It requires precise alignment and 3D measurement solutions to ensure optimal performance and longevity. When 3D Metrology Solutions were brought on to work with RMS, we decided to use virtual assembly techniques with the help of PolyWorks software.

This method would allow us to measure the new turbine, along with the existing housing, to maintain all clearances. This was supported by CMM measurement, which means emplloying the use of a CMM (coordinate measuring machine). It guaranteed a high level of accuracy, significantly reducing installation time and costs. 3D scanning would help to confirm quality control.

Project objectives

This was what we set out to achieve while working with RMS:

• Install three new turbines within the existing housing, without compromising the structural integrity.
  
  

• Maximise performance by ensuring all clearances were maintained, to avoid any interference or operational issues.
  
  

• Streamline the installation process, via advanced 3D measurement solutions and virtual assembly techniques.

Methodology

We used a range of CMM measurement devices and software:

• PolyWorks software

• AT960 Leica Laser Tracker with T-probe

• 3D scanning tools - AS1/AS1-XL paired with a AP21

These were the steps we followed below.

1. Initial assessment and planning:

• We reviewed the existing turbine and housing specifications

• We identified the critical areas for measurement

• We developed a measurement and assembly plan
  
  

2. Data acquisition:

• We used laser trackers and 3D laser scanners, to capture the geometries of the new turbine and existing housing
  
  

3. Data processing and analysis:

• We confirmed that the new turbine model aligned with the existing housing model

• We analysed the clearances and identified potential interference points

4. Virtual assembly:

• We simulated the installation of the new turbine within the existing housing

• We adjusted the position of the turbine for the best possible fit

• We verified the clearances and adjustments as needed

5. Installation and verification:

• We carried out the physical installation of the new turbine, based on the virtual assembly plan
  
  

• We used the laser tracker to position and align the turbine in the housing, to ensure maximum performance
  
  

• We oversaw the final verification of clearances and alignment, using manual measurement solutions

Challenges and solutions

The challenges we were aiming to overcome on this project were:

• Data accuracy
  
  

• Complex geometries and hard-to-reach areas
  
  

• Data processing and alignment
  
  

• Final verification and adjustments

These were the solutions we achieved:

• We used high-accuracy 3D solutions, comprising laser scanners and laser trackers, for a high level of accuracy in data acquisition. We conducted extensive 3D scanning and took multiple 3D measurements from different angles. This allowed us to capture comprehensive and accurate data.
  
  

• We created a detailed measurement plan, including strategies for accessing and measuring challenging areas.
  
  

• We created consistency by establishing and using key reference points and dimensions for alignment. We also used advanced alignment and analysis features in PolyWorks, to facilitate accurate data processing.
  
  

• We monitored the installation of the turbine to finetune the alignment, resulting in maximum performance for the customer.

Outcomes

Accuracy and precision

By using PolyWorks software and advanced measurement solutions, we ensured a high level of accuracy and precision in the installation process. We confirmed that the clearances were within the specified tolerances, while optimising the alignment of the turbine so that it would perform well.

Time and cost savings

We led a virtual assembly process that significantly reduced the installation time and was efficient in terms of costs. By identifying potential issues and making adjustments in the virtual environment, we minimised the need for rework and adjustments during the physical installation.

Performance and reliability

We installed the new turbine with clearances and alignment, for maximum performance and reliability. The precise installation contributed to reduced wear and tear, extending the life of the turbine and associated components.

Conclusion

The installation of the new turbine proved to be a successful, efficient project for RMS. This was largely supported by the virtual assembly techniques we employed and the use of PolyWorks software. Through our team’s advanced measurement and analysis capabilities, 3D Metrology Solutions achieved precise alignment and clearance verification. Ultimately, this resulted in optimal performance and reliability for RMS.

This project demonstrated the value of leveraging modern technology and 3D solutions to enhance industrial processes, reduce costs, and improve outcomes.