We continue in our blog post series about 3D Scanning and Reverse Engineering, this time talking about some work performed in the past, that helped our customers to overcome some technical challenges with the help of our engineering expertise and the use of these advanced and well-known tools.

Reverse Engineering in Action

Reverse engineering isn’t just a theoretical concept; it’s a dynamic process with tangible results. In this section, we’ll explore real-world case studies and success stories where reverse engineering played a pivotal role in solving complex challenges and driving innovation.

Case Study 1: Hydropower Plant Efficiency

Challenge: A hydropower plant was facing a significant challenge in maintaining the efficiency of its hydroelectric turbines. Over time, wear and tear had reduced the performance of the turbine blades, leading to energy losses. The unit is located in Canada, and is a horizontal Kaplan turbine rated at 3 MW. Cavitation and high vibration issues limited it to a maximum capacity of 2 MW, and was operating like that since it commissioning in the late 1980s.

Solution: Reverse engineering proved to be the ideal solution. Using 3D scanning technology, engineers meticulously scanned the turbine blades, capturing their precise geometries. This data was then processed to create detailed CAD models of the blades. After that, with the help of a turbine designer and several CFD iterations, the blades’ design was slightly changed, addressing the cavitation issue, and as well the runner hub was slightly modified, adding a “ring” to help with the flow of the water through it, to make it more laminar and avoid the formation of a vortex close to one end of the hub.

Outcome: Armed with accurate CAD models, the hydropower plant was able to manufacture replacement turbine blades that precisely matched the new specifications. The new blades restored the turbine’s efficiency, maximizing power generation from the flowing water. This case exemplifies how reverse engineering can rejuvenate aging infrastructure, ensuring the continued production of clean energy.

Case Study 2: Agricultural Innovation

Challenge: A blueberry farm faced an ongoing challenge with its collector machines. The “claws,” which played a crucial role in gently plucking ripe blueberries from bushes, suffered from rapid wear and tear. Traditional manufacturing methods for replacement claws were costly and time-consuming.

Solution: The farm turned to reverse engineering for a game-changing solution. Using 3D scanning technology, they meticulously scanned the original “claws” to capture their precise shape and dimensions in the form of a point cloud. This digital representation served as the foundation for the redesign process.

Redesign Process: Engineers employed CAD modeling to optimize the design of the “claws.” They focused on enhancing their durability and wear resistance, making them more efficient at collecting blueberries while minimizing damage to the fruit.

Outcome: The redesigned “claws” not only outperformed their predecessors but also proved to be significantly more cost-effective. Leveraging 3D printing technology, the farm was able to manufacture these improved “claws” quickly and affordably. The 3D-printed parts exhibited excellent wear resistance and longevity, resulting in reduced maintenance costs and increased blueberry harvest efficiency.

This case study underscores how reverse engineering, coupled with 3D scanning and printing, can revolutionize agricultural practices. By optimizing critical components and reducing production costs, it exemplifies the transformative potential of these technologies in enhancing productivity and sustainability in the agricultural sector.

Case Study 3: Historic Hydropower Restoration

Challenge: A hydropower generation plant, boasting over a century of operation, faced a daunting challenge: five crucial components, including the curb plate, thrust bearing pad holder, operating ring, head cover, and thrust bearing block, had no existing drawings or documentation. Over the years, the lack of accurate information hindered maintenance, efficiency, and the plant’s overall reliability.

Solution: The plant’s management recognized the need for a comprehensive solution. They turned to modern technology, specifically structured light scanning, to address this complex issue. Structured light scanners were employed to meticulously capture the precise geometries of these critical components.

Reverse Engineering Process: With the point cloud data from the structured light scans, engineers embarked on a journey of reverse engineering. They transformed the data into detailed, digital twins of the components, complete with accurate dimensions and specifications. This digital transformation allowed for the creation of much-needed reference drawings.

Improvements and Suggestions: The reverse engineering process did not stop at documentation. Engineers also leveraged their expertise to suggest improvements to the components. Using the digital models as a foundation, they proposed enhancements that would boost efficiency, extend the lifespan of the components, and increase overall plant performance.

Outcome: The restoration efforts were nothing short of transformative. The hydropower generation plant now had accurate reference drawings for the once-undocumented components, ensuring efficient maintenance and repairs. Moreover, the suggested improvements were implemented, resulting in enhanced energy generation and the plant’s ability to continue serving its community for generations to come.

Case Study 4: Hydropower Efficiency Restoration

Challenge: In a hydropower plant dealing with extremely abrasive water laden with sediment, the pelton runners suffered severe erosion damage. The runners had deteriorated significantly due to prolonged exposure to abrasive particles, creating a rapid degradation in less than 10,000 hours of operation. The pattern of damage was puzzling and necessitated immediate attention.

Solution: Recognizing the urgency and complexity of the issue, a team of engineers and technicians embarked on a mission to restore the damaged components and improve the overall efficiency of the turbine. They brought with them advanced 3D scanning equipment to capture the existing conditions of the runners and surrounding components.

Reverse Engineering and Damage Analysis: After just a couple of days on-site, the team had acquired precise 3D scans and measurements of the damaged pelton runners and surrounding structures. Through reverse engineering, they created digital models of the components and analyzed the erosion patterns in detail.

Repair Procedure and Design Improvements: Armed with a comprehensive understanding of the erosion damage, the team developed a meticulous repair procedure to restore the damaged runners to optimal condition. Additionally, they took the opportunity to design improvements for the pelton runner and water injectors to mitigate future erosion issues.

Advanced Analysis for Efficiency Enhancement: The engineers in this case are going a step further, will be creating a Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) models to simulate the flow of water through the turbine and assess structural integrity. These models will be used to fine-tune the design modifications for maximum efficiency.

Expected Outcome: The restoration efforts are expected to lead to a significant improvement in the efficiency and lifespan of the pelton runners. By understanding and addressing the erosion patterns, the team was able to recommend not just a proper repair procedure with stronger materials, but as well some adjustments and improvements on the water injectors. The design improvements not only will reduce wear and tear but also enhance the overall performance of the hydropower turbine, resulting in increased energy generation and cost savings.

This case study exemplifies how 3D scanning, reverse engineering, and advanced analysis can play a pivotal role in addressing complex challenges in the hydropower industry. It underscores the importance of proactive maintenance, damage analysis, and design optimization in ensuring the reliability and efficiency of critical components in hydropower plants.