Polysius
Creating precise technical 3D models
of your assets.
Key figures strip
- Millimetre
- Precision, which is what makes wear measurement possible
- Millions
- Of measurement points, recorded contactlessly
- 3 uses
- Plant design · wear measurement · thermal analysis
- No contact
- Ongoing production is not affected
- Any software
- File format compatible with all kinds of software
How We Capture It
A laser scanner on the ground for what you can walk to; an industrial drone for what you cannot. Together they produce a realistic representation of the required areas — including areas that are inaccessible.
| Accurate laser scanners | For components and interiors. Millions of measurement points recorded contactlessly, precise to the millimetre |
| High-resolution industrial drones | For structures, roofs, towers and terrain — reaching what would otherwise need scaffolding, a crane or a permit |
Page statement: this contactless measurement method does not affect ongoing production and can record even inaccessible areas. That is why a survey can happen when it is useful — during planning — rather than only during the shutdown it was supposed to prepare.
Application 01 — PlantScan 3D for Plant Design
3D structural surveying of a plant considerably simplifies and reduces planning work. When designing plants, the data recorded can be used to create 3D models, and interfering edges can be detected earlier.
Time-consuming and personnel-intensive re-measurements are not required. Conversion parts can be accurately planned, manufactured and installed without major adaptation work. The risk of unplanned stoppage times is minimized. This contactless measurement method does not affect ongoing production and can record even inaccessible areas.
Application 02 — PlantScan 3D for Wear Measurement
PlantScan 3D assists in analyzing the wear on the roll bodies of high-pressure grinding rolls and the crushing elements of gyratory crushers, through completely and rapidly laser-scanning these components. The scan is processed and displayed to allow wear analysis. As a result, maintenance work and service lives can be calculated more accurately.
Complete and rapid scanning of the component, rather than spot measurements with a gauge
Processed and displayed for wear analysis — a wear picture, not a list of readings
Maintenance work and service lives can be calculated more accurately
Millimetre precision is what makes this possible; a coarser method could not resolve the wear
Cross-link on the page: “How wear material choice follows from this” → Spare Parts Management, wear materials section, where the polycom® wear protection program and its three concepts are described.
Application 03 — PlantScan 3D with Thermal Overlay
With the help of thermal sensors attached to a drone, PlantScan 3D enables 3D models of your plant to be created with a thermal overlay. So you can detect heat leakages, pipe congestions, or just document the current situation of your plant.
Page framing: the geometry and the temperature end up in the same model, so a hot spot has a location rather than just a reading.
The Problem It Removes
Anyone who has planned a conversion into an existing building knows the pattern: somebody goes out with a tape measure, the drawing is made, then a detail turns out to be wrong and somebody goes out again. Four costs disappear with a 3D model.
| Re-measurement trips | Time-consuming and personnel-intensive re-measurements are not required; every new question is answered from the model that already exists |
| Adaptation work on site | Conversion parts can be accurately planned, manufactured and installed without major adaptation work |
| Surprises during assembly | Interfering edges are detected earlier; the risk of unplanned stoppage times is minimized |
| Access problems | The method can record even inaccessible areas and does not affect ongoing production |
polscan® or PlantScan 3D?
Both are precision measurement services from Field Services, and they are easy to confuse. They answer different questions on different objects.
| polscan® | PlantScan 3D | |
| What it measures | The geometry of a rotary kiln: axis deviation, shell deformation, eccentricity, ovality | The three-dimensional shape of anything: plant, process systems, terrain, individual components |
| Method | Optoelectronic measuring method, on the running kiln | Laser scanners and high-resolution industrial drones, producing a point cloud |
| Typical question | “Is my kiln still straight, and what is that doing to my refractory?” | “What exactly is in this building, and will the new machine fit?” |
| What you receive | Measurement records, on-site documentation and a written report with recommendations | A 3D model in a file format compatible with all kinds of software |
| Also used for | Kiln statics calculation; adjustment of supporting roller bearings | Wear measurement on HPGR roll bodies; thermal analysis |
Closing note on the page: in practice they are often used together on the same project — PlantScan 3D captures the building and surroundings so new equipment can be designed into it, while polscan® establishes whether the kiln that stays is still within tolerance.
Your Service Advantages
Contactless recording of millions of measurement points
Fast and safe measuring method for supporting plant design
Precision to the millimetre allows wear measurement
Thermal overlay of the 3D model for thermal analysis
File format compatible with all kinds of software
The last point is given emphasis on the page: the model is the customer's to use in their own tools, not locked into ours. It is the advantage people forget to ask about until it is too late.
The scanners can not only detect wear with millimetre precision, but also easily document the current plant situation.