Heat, Dust, and Complex Geometries: The Project That Pushed Limits

When Thriveni, a diversified mining company with operations in India, Indonesia, and Africa, reached out for a new project, the mission looked straightforward at first glance: acquire the 3D measurements of a series of massive mining components at its Salem facility to evaluate wear, prepare for refurbishment, and ensure accurate reassembly.

The parts measured up to six meters in diameter, some curved, some recessed, and all difficult to handle. The work had to be done outdoors. There was no controlled environment, no stable flooring, and no protection from sun, heat, dust, or unpredictable weather.

“We immediately knew sunlight was going to be our biggest enemy,” explained Janakiraman Kanthinathan, who oversaw the project. “Tracking loss in direct sun is no joke, especially around noon. If the system can’t see properly, you’re done.”

The geometry of the parts added even more difficulty. Many surfaces were hidden behind deep recesses or curves. Others were positioned at angles that made access awkward. And because the client insisted on full coverage inside and out, even the smallest pockets had to be captured.

Target placement became a major problem. With the company’s previous 3D measuring tech, 3D scanning large parts meant applying thousands of reflective targets. On rusted, dusty metals exposed to heat and rain, targets fall off. When users lose targets, they lose time and sometimes entire data sets.

“We could see it immediately,” said Janakiraman. “If we had used our legacy 3D scanners, we would have spent half a day just placing targets. And there was no guarantee they would stay on, especially in the heat.”

To make the project possible, the team adjusted the workday around the sun. They began at four in the morning, scanning until the heat and glare became too intense. In the evening, once the light softened, they picked up where they left off and worked until late at night. The schedule wasn’t ideal, but it was the only way to maintain stable 3D scanning in outdoor conditions.

The team also reorganized their entire approach to maneuverability. Instead of treating each component as a single object, they broke the surfaces into sections and mapped out a path that would allow them to work around dips, curves, and narrow spaces without losing sight of the measurement field.