[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 way to accelerate reverse engineering, iterative design, and other CAD-related applications in modern times. In industrial maintenance and repair, accurate measurements are crucial for resolving equipment failures and improving operational efficiency. Metrology 3D scanners like the FreeScan UE 11 are ideal tools in these situations because 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 a mill component? Let's take a look at their case study!

Problem: Damaged Trunnions

ATEGROUP's client uses SAG mills in their value chain to grind materials. To maintain client anonymity, not many details are revealed, but it is clear that 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 found that their SAG mill was damaged; material was leaking from the machine during grinding. They quickly discovered that the machine's feed and discharge trunnions, crucial components 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 leverage 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 trunnions

2. Generate precise 2D drawings of the trunnions and drive system

I. 3D Scanning

First, ATEGROUP 3D scanned the SAG mill components. For large parts, approximately 2.5 to 3 meters, the portability and speed of the 3D scanner are crucial. The team was able to easily 3D scan around the entire mill using the lightweight FreeScan UE 11.
 

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 intersecting laser lines, capturing data at a rate of 1.35M 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 used Geomagic Design X to extract the required measurements and geometries.

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

 

III. Simulation Analysis

Finally, ATEGROUP's engineers conducted a simulation analysis using the scanned CAD model to determine the optimal repair solution. Through their simulation software, they replicated operating conditions and applied stress factors to the digital trunnions, 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 for simulation analysis in software

Results

With 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 the components for subsequent production

For the first point, the team recommended using A36 steel lining plates. This provides proper structural support to address the leakage problem, and detailed and accurate 2D drawings enable customers to ensure the correct production of parts; compared to manual measurement and drawing, it saves customers a lot of time and resources.

 

With 3D scanning and suitable software, engineers can generate 2D drawings with just a few clicks, allowing them to spend more time on other more valuable projects
 

Digital simulation is an effective method for providing durable and robust repairs for industrial components and machinery. Accurate simulation requires precise 3D data.

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

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

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