Crane Component Inspection with SCANTECH's 3D Scanning Solutions

The heavy machinery industry plays a crucial role in infrastructure development, construction, and heavy-duty projects. Cranes, as one of the most critical lifting equipment, require precise engineering and stringent quality control to ensure safety and performance.

With advancements in technology, manufacturers are constantly seeking improved methods for quality assurance, especially in the measurement and inspection of key components. Traditional measurement techniques often struggle to meet the high accuracy, efficiency, and digitization demands of modern industrial applications.

The client in this case study is one of China's largest manufacturer of automotive cranes, all-terrain cranes, specialized fire trucks, aerial work platforms and more. Its products meet both national and international industry standards, earning widespread recognition. To stay competitive, the company consistently invests in advanced measurement and inspection technologies to improve product quality.

Features of the Crane Telescopic Boom’s Cover

The crane telescopic boom’s cover is used to cover the joints between boom sections and other critical stress-bearing areas, providing protection, sealing, and structural reinforcement. Accurate measurements of the boom covers are essential to ensure proper fitment and functionality in the crane.

Measurement Challenges

These covers vary in length from 0.7 m to 14 m and weigh between 95 kg and nearly 4,000 kg. The measurement requirements for the telescopic boom covers include assessing parameters such as straightness, deflection, opening dimensions, and symmetry. Despite its seemingly simple structure, the part is prone to deformation due to gravity and external forces, making it difficult to measure accurately. The large size of the component also necessitates a diverse set of measurement tools, further complicating the inspection process.

Limitations of Previous Measurement Methods

Previously, the machinery manufacturer relied on traditional measurement tools such as tape measures and calipers for inspection.

For measuring straightness, a quality inspector must use a specialized gauge and manually measure the distance between a reference line and selected points along the cover’s edge at 1.5-meter intervals, recording only the maximum deviation. This approach is tedious and lacks comprehensive data coverage.

These methods posed several challenges:

Low Accuracy: The precision of manual measurements was insufficient for stringent quality control.

Inefficiency: Multiple measurement tools were required, leading to time-consuming inspections.

Subjectivity: Results were influenced by the operator's experience and technique, leading to inconsistencies.

Data Management Issues: Measurements were not digitized, making it difficult to track and analyze trends over time.

SCANTECH's 3D Scanning Solution

To tackle these challenges, SCANTECH provided the machinery manufacturer with the TrackScan Sharp-S 3D scanning system, a cutting-edge solution that redefines crane component inspection with exceptional precision and efficiency.

The TrackScan Sharp-S is designed for high-speed, long-range measurement of large-scale parts. Featuring 25-mp industrial cameras and advanced onboard processors for edge computing, it delivers unmatched accuracy and performance. With a tracking distance of up to 8.5 m and a measurement range of 135 m³, it pushes the boundaries of optical measurement.

This measurement system is highlighted by its robust performance including 99 laser lines, and a measurement rate of up to 4.86 million measurements/s, offering highly precise and reliable measurement results.

Scanning Process

Unlike traditional methods that require markers, the SHARP S enabled marker-free and non-contact scanning—completing the process in just 10 minutes.

The 3D scanner generated a 3D point cloud in real time, measuring key dimensions such as straightness and symmetry.

The data were used to analyze deformation trends in the future, providing valuable insights for quality control and product improvement. With a single click, the report was generated and exported.

By integrating the SHARP-S 3D scanner into its workflow, the company achieved faster, more accurate measurements, ensuring consistent quality and efficiency in production process.

Benefits of SCANTECH's 3D Scanning Solution

Wireless & Convenient

The TrackScan Sharp-S 3D scanner’s portable and user-friendly design made it easy to perform quick, on-site measurements without the hassle of a complex setup. Its wireless capability allowed for unrestricted movement, enabling efficient data capture.

High Accuracy & Comprehensive Data

The system provided highly precise measurements with a maximum volumetric accuracy of 0.048 mm (10.4 m³), capturing all required dimensions with minimal error. The precise results are ensured thanks to its metrology-grade hardware and an innovative in-housed developed algorithm.

Objective & Repeatable Results

Unlike manual methods, 3D scanning eliminated human error and ensured consistent measurement accuracy across inspections.

Digitalization & Data Management

The scanning process generated 3D data, facilitating easier analysis, quality control, and trend tracking. The digital nature of the results allowed seamless integration with Manufacturing Execution Systems (MES) for future automation and enhanced quality control.

Full-field Inspection for Quality Assurance

The TrackScan Sharp-S could scan the entire component without needing to be repositioned frequently, streamlining the workflow. Instead of sampling, it allowed for full-batch inspection, ensuring a higher pass rate and reducing the risk of defects.

Conclusion

By adopting SCANTECH's TrackScan Sharp-S 3D scanning solution, the machinery manufacturer significantly improved its inspection process for crane telescopic boom covers. The transition from traditional manual measurements to digital 3D scanning enhanced accuracy, efficiency, and data management capabilities. This upgrade not only ensured superior product quality but also positioned the company for future automation and intelligent manufacturing. As heavy machinery manufacturers continue to embrace cutting-edge technology, 3D scanning solutions like those provided by SCANTECH will become integral to quality assurance and production optimization.