[3D Scanning Application] Helping Clients Restore SAG Mills with 3D Scanning and CAD Simulation - SHINING 3D X ATEGROUP

【3D Scanning Application】Using 3D Scanning and CAD Simulation to Help Customers Repair SAG Mills - SHINING 3D X ATEGROUP

3D scanning for simulation analysis is an efficient method to accelerate modern reverse engineering, iterative design, and other CAD-related applications. In industrial maintenance and repair, accurate measurement is crucial for resolving equipment failures and improving operational efficiency. Metrology 3D scanners like the FreeScan UE 11 are ideal tools for these situations, as they can capture accurate and precise 3D data in the shortest possible time.

How did ATEGROUP use the FreeScan UE 11 3D scanner to repair components of a grinding mill? Let's take a look at their case study!

Problem: Damaged Trunnion

ATEGROUP's client uses SAG mills in its value chain to grind materials. To maintain client anonymity, not too many details were revealed, but clearly, material preparation is always a critical part of production. The quality of the material lays the foundation for the quality of the product.

The client discovered that their SAG mill was damaged; material was leaking from the machine during the grinding process. They soon found that the machine's feed and discharge trunnions, critical components responsible for material transfer, had cracked.

Due to the material leakage, the team faced serious problems. This was not only about operational efficiency but also about employee safety.

Solution

To repair the trunnions, the client chose ATEGROUP, a Colombian company that provides 3D scanning and reverse engineering services. They utilize a range of SHINING 3D scanners to provide these services.

ATEGROUP set two goals for this project:

1. Determine the most suitable technique for reinforcing the trunnion

2. Generate accurate 2D drawings of the trunnion and drive unit

I. 3D Scanning

First, ATEGROUP 3D scanned the SAG mill components. For large components, approximately 2.5 to 3 meters in size, the portability and speed of the 3D scanner were important. The team was able to easily use the lightweight FreeScan UE 11 to 3D scan around the entire mill.
 

Then, after placing markers on the metal surface of the mill, the team quickly captured additional data using the scanner. The FreeScan UE 11 projects 11 crossed laser lines, capturing data at a rate of 1.35 million points per second.

 

II. Reverse Engineering

Based on the 3D point cloud obtained in the previous step, the team then proceeded to the reverse engineering phase. They processed the scanned data and extracted the necessary measurements and geometries using Geomagic Design X.

ATEGROUP meticulously recreated the parts in a digital 3D environment: Parts in CAD software after 3D scanning for simulation analysis

 

III. Simulation Analysis

Finally, ATEGROUP's engineers performed simulation analysis using the scan-based CAD models to determine the optimal repair solution. Through their simulation software, they replicated operating conditions and applied stress factors to the digital trunnion, allowing them to analyze the behavior of each part under different scenarios, evaluate potential failure points, and determine the most effective repair method.

 

3D scanned view used for simulation analysis in the software

Results

With the FreeScan UE 11, ATEGROUP was able to achieve two goals after reverse engineering and simulation analysis:

1. Proposed the most effective and robust trunnion repair solution

2. Provided accurate 2D drawings of components for subsequent production

For the first point, the team recommended using A36 steel liner plates. This provides the correct structural support to solve the leakage issue, and the detailed and accurate 2D drawings allow the client to ensure correct part fabrication; compared to manual measurement and drawing, it saves the client a significant amount of time and resources.

 

With 3D scanning and appropriate software, engineers can generate 2D drawings with just a few clicks, freeing up more time for other beneficial projects.
 

Digital simulation is an effective way to provide long-lasting and robust repairs for industrial parts and machinery. However, accurate simulation requires precise 3D data.

By using the FreeScan UE 11 3D scanner to capture metrology-grade data of the SAG mill, ATEGROUP was able to quickly identify the best solution for the client, resolve critical issues, restore production, and ensure employee safety.

SHINING 3D's precise and portable 3D measurement solutions can help you streamline your maintenance and repair processes.

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