Automated 3D Scanning for Emission Control Component Inspection

How can manufacturers maintain precision and consistency while meeting ever-stricter environmental regulations? Many still rely on traditional inspection methods that are slow, and and prone to human error. Others have turned to automated systems, only to find that many lack the flexibility and accuracy needed for large or complex parts. As quality standards rise, the challenge becomes clear: how can manufacturers achieve both speed and precision in their inspection process?

One of India's largest diesel and natural gas engine manufacturers, operating across Engine, Power Systems, and Distribution units, has driven technological innovation in clean, efficient engines. The company produces oxidation catalysts, particulate filters, and SCR technologies—critical components for controlling harmful emissions and ensuring long-term engine reliability.

Project Background and Objective

Given the high-performance requirements of emission control components, the manufacturer needed to perform precise inspections and maintain strict control over GD&T (Geometric Dimensioning and Tolerancing) and CTQ (Critical-to-Quality) parameters. The part under inspection was a non-machined component measuring approximately 300 mm in diameter. The customer required a fully automated, marker-free 3D scanning solution that could deliver high accuracy while ensuring a short inspection cycle time.

Proposed Solution

To meet these requirements, SCANOLOGY proposed an automated 3D scanning system that combined advanced optical tracking technology with collaborative robotics. The solution integrated the following components:

3D Scanner: TrackScan-Sharp optical 3D scanning system 

Cobot: Fanuc CRX 10iA

Inspection Software: PolyWorks

Scanning Software: DefInsight-AM

The TrackScan-Sharp system was selected for its ability to deliver high-precision, markerless 3D scanning. Unlike traditional scanners that rely on reference targets, the TrackScan series uses optical tracking to locate and capture 3D data in real time. This feature made it ideal for the customer's requirement to eliminate markers and streamline the process.

Process Flow and Implementation

The scanning process was carefully designed to maximize data completeness and operational efficiency.

· Preparation

The part was mounted on an elevated fixture to allow 360-degree accessibility. This setup ensured that 95–100% of the surface data could be captured without repositioning the component.

· Cobot Movement

The collaborative robot was programmed to move the TrackScan-Sharp scanner around the part. Its motion path was optimized to achieve complete surface coverage while maintaining safe distances and optimal scanning angles.

· Data Acquisition

The TrackScan-Sharp system acquired the STL data within 2 minutes, efficiently capturing all required features.

· Inspection and Analysis

The scanned data was processed in DefInsight-AM software and compared against the original CAD model in PolyWorks to verify GD&T and CTQ parameters.

The entire workflow—from setup to data comparison—was seamlessly executed within SCANOLOGY's integrated solution framework, allowing the customer to inspect parts faster and more accurately than before.

Challenges Encountered

While developing the automated system, the project team faced several challenges:

Achieving full coverage of the part's complex geometry within the cobot's reach required precise motion planning and optimization of scanning paths. To meet the target cycle time of under two minutes, the team had to balance scanning accuracy, cobot speed, and data density—a demanding task given the component's size and shape. Additionally, capturing complete geometry from multiple angles without blind spots called for meticulous adjustment of both the cobot's trajectory and the scanner's orientation.

Despite these challenges, SCANOLOGY's engineering team successfully developed a robust and efficient workflow that met the customer's quality and time requirements.

Advantages of Our 3D Solution

Our system provided several key benefits compared to traditional inspection methods and competing solutions:

· Fast and Efficient Scanning

Thanks to its innovative fast scanning mode powered by triple-cross technology with 81 laser lines and high measurement rate of up to 6 million measurements/s, The TrackScan-Sharp achieved a full scan within just two minutes, enabling high inspection throughput.

·Markerless Operation

With advanced optical tracking, it eliminated the need for markers and simplified the process and reduced preparation time. The marker-free scanning process was also completely non-contact, ensuring no risk of damage to the parts.

·Ease of Integration

The solution was designed as a one-stop system, covering cobot programming, scanning, and inspection within a unified workflow.

·High Accuracy and Reliability

The TrackScan-Sharp delivered significantly higher accuracy (up to 0.025 mm) than camera-based systems, ensuring reliable dimensional verification.

·Low Setup Time

The system was quick to install and easy to program, allowing operators to begin scanning with minimal training.

Comparison with Conventional Market Solutions

Before adopting our system, the customer evaluated other camera-based solutions available in the market. However, these systems failed to meet critical performance expectations. Some solutions offered automated scanning capabilities but lacked the precision required for tight GD&T control. Moreover, its setup and cycle times were substantially longer, leading to inefficiencies in production workflows.

In contrast, SCANOLOGY's automated 3D scanning system delivered the best balance between speed, precision, and operational simplicity, allowing the manufacturer to significantly enhance its inspection efficiency while maintaining strict quality standards.

Outcome and Impact

The implementation of SCANOLOGY's automated solution revolutionized the customer's inspection process. The company achieved:

• Improved accuracy in dimensional control
• Reduced inspection cycle time
• Simplified programming and setup
• Greater consistency in data quality

By integrating SCANOLOGY's TrackScan-Sharp system with the cobot and PolyWorks inspection software, the customer now benefits from a fast, intelligent, and reliable inspection workflow that supports its ongoing efforts to reduce emissions and uphold the highest standards of engine component manufacturing.