Proram has performed precision laser scanning and NDT quality analysis of a KOMATSU crusher shaft to identify the cause of failure.
Project description
- Client: Komatsu Poland – based in Tychy,20 Murarska Street, Poland.
- Challenge: After a short period of operation of the crusher, the bearings failed and the shaft journals seized. As the problem occurred shortly after replacement, there was a suspicion of faulty assembly or faulty component manufacture. Proram’s task was to take precise measurements to determine the cause of the damage.
- Solution: Proram performed non-contact scanning with a Hexagon Absolute Arm RA8525 laser scanner to accurately analyse the damaged components. The collected data was digitally processed into a 3D CAD model for comparison with the nominal geometry of the shaft.
- Result: Komatsu obtained precise shaft geometry data within one day. The rapid diagnostics reduced the time and costs associated with conventional inspection methods. Komatsu was able to quickly identify the cause of the problem and plan further steps to prevent similar failures in the future.
Project details
- Project objectives:
- To identify the cause of the crusher shaft failure by accurately scanning and comparing the geometry with nominal values.
- Verification of whether the damage was due to faulty installation or faulty shaft design.
- Description of the technology and processes used:
- Non-contact laser scanning using Hexagon Absolute Arm RA8525 was used.
- Measurements were performed in several baselines due to the large distance between the shaft ends and the limited length of the measuring area.
- To reduce the risk of errors, sections of the shaft with and without visible damage were measured separately. The point cloud obtained from the scan was then digitally transformed into a 3D CAD model.
- Implementation and implementation stages:
- The scanning was performed at the customer’s premises in Tychy. The data collected from the measurement was then processed into a 3D CAD model for comparison with the nominal geometry.
- Digital color deviation maps were used to quickly visualize the measurement results. This method facilitates the evaluation of discrepancies.
Results and benefits
- Results obtained:
- The measurements showed that the damage was mechanical in nature, with cavities on the shaft surface ranging from 0.3 to 0.4 mm. These results confirmed the axiality and total run-out problems of the shaft, which had a direct impact on the bearing damage.
- Customer benefits:
- Traditional methods of analysing such large components as the crusher shaft (of considerable length and weight) would have involved cumbersome and expensive disassembly and the use of specialised CNC machines. The whole process would take about 1-2 weeks and generate high operating costs.
- Laser scanning using the Hexagon RA8525 mobile measuring arm, allowed Proram engineers to reduce the analysis time from weeks to one working day.
- The scanning took place at the customer’s premises. On the very day of measurement, results and precise geometry mapping were obtained. This minimised machine downtime and reduced operating costs by around 70%.
Customer feedback
‘Working with Proram provides us with valuable experience and knowledge of modern measurement technologies. Their flexibility, willingness to take on challenges and responsiveness make Proram a partner we can count on.
We confidently recommend Proram’s services to anyone looking for reliable and professional solutions in the fields of surveying, 3D scanning, reverse engineering,’ wrote a representative of Komatsu Mining Group in the reference letter.
A link to the full reference letter can be found in the Projects section .
