3D scanning improves inspection and maintenance of race cars

Keeping a racing car in peak condition during competitions is crucial, not only for performance but also for safety. Ensuring the driver and other competitors stay protected requires meticulous attention to detail and advanced technology. This is where Scantech’s portable 3D laser scanners prove invaluable. These innovative 3D scanners deliver fast and highly accurate measurements of race car components. By leveraging this cutting-edge technology, teams can maintain optimal performance and safety standards for their vehicles. Additionally, the precision of 3D scanning simplifies routine inspections and maintenance processes, saving valuable time and reducing costs along the way.

KSCAN-Magic portable 3D scanner

The BME Motorsport racing team precisely 3D scanned the race car components and created 3D models to ensure they were in good condition and gain insight into real working conditions.

The 3D laser scanner used in this case is the KSCAN-Magic, one of the first 3D scanners to combine infrared and blue lasers in a single instrument. With two sets of high-definition industrial cameras, it can meticulously perform 3D scanning.

It offers five standard working modes:

• Large area scanning (Global Initiative infrared laser)

• Fast scan (blue laser crossed lines)

• Fine scanning (blue parallel laser)

• Depth scan (single blue laser)
• Integrated photogrammetry system

3D scanning to reshape a crankshaft

The crankshaft is a vital part of internal combustion engines that converts the reciprocating motion of the pistons into rotary motion. Using methods such as strength simulations and balance testing, engineers can evaluate and optimize crankshaft design and performance.

Since the crankshaft has complicated geometries, an accurate crankshaft model is critical to ensure accurate strength simulations and balance tests.

The engineer used the Scantech KSCAN-Magic portable composite 3D scanner to capture the geometry of the crankshaft from different angles and saved the scanned data into the software to reshape the crankshaft.

3D scan to inspect a rear frame

A rear chassis affects the handling, stability and performance of the car. A well-designed and properly maintained rear chassis can help a car achieve optimal balance and aerodynamics.

After a year of use, the rear chassis may deform, compromising the safety and efficiency of the racing car.

The engineer used KSCAN-Magic to acquire 3D data of the rear chassis. The acquired data were compared with those obtained one year earlier. In comparison, they checked whether the frame suffered any deformations during last year’s racing season.

It also helped identify the extent of the damage and see if it is fit for another season of racing. You can see that it has not suffered any major deformations and the car is competitive again this season.

Engine block design

Additionally, they performed a scan of the lower engine block. For such complex parts, it is a significant advantage to create a CAD model based on the 3D data generated by the 3D scanner, rather than modeling it from scratch.

The geometry of the engine block is very complicated and designing, for example, a model-free lubrication system is a big challenge. The scanned models facilitated the placement of the lubrication system and allowed us to verify that all intended parts were suitable or if further modifications were necessary.

Inspection of a monohull structure

Before production the internal surface of the monocoque was damaged, resulting in small inaccuracies in the final part.

It was therefore essential to scan the monocoque, to compare the part actually made with the model and detect any errors. Furthermore, they could easily verify the precise position of the frame and the connection points to the frame by comparing the two models.

Advantages of the 3D scanning solution

The KSCAN-Magic 3D scanner stands out among its competitors with its composite functions, which are suitable for 3D scanning small areas, complex details and large parts. It can be installed on site to take measurements wherever needed, as it is portable and compact.

With a measurement speed of up to 1.65 million measurements/s and an accuracy of up to 0.020mm, it can ensure that the acquired 3D data can meet users’ stringent requirements.

Thanks to the 3D scanner’s high-precision measurements, the engineer obtained 3D data with an accuracy of up to 15-30 microns to create precise models.

As a result, the CAD models created were as realistic as possible. High-tech 3D scanning increases the efficiency and comfort of maintaining a racing car for maximum performance