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In the paper the application of ToF laser scanner in measurements of geometrical parameters of a boiler drum used in a power plant is presented. These parameters are required during renovation works, for verification of correctness of annealing process and optimization of the process of mounting a mechanical steam–water separation. The currently used separations are tightly placed in a boiler drum, so a welding process is not required anymore. This approach saves the time of renovation works, but the geometry of a separation has to be precisely matched against the geometry of the drum to ensure the tightness of connection and, in consequence, to ensure stability of steam parameters (pressure and temperature). Renovation works may include heating processes, after which geometry should also be carefully verified as improperly performed can lead to buckling of a boiler drum. In the presented approach ToF scanner provides cloud of points, which has been subjected to a set of post-processing operations including stitching, cylinder fitting, projection 3D data onto 2D map, 2D data interpolation and filtering. As the result, the required dimensions and tolerances are obtained and are ready for further implementation. [ABSTRACT FROM AUTHOR]

• We proposed an improvement for the crank shaft geometry measurement system. • We proposed models to support large crankshafts geometry measurements. • We used these models to map the reaction forces in the flexible crankshaft. • We calculated relative errors and R2s of the models for an example crankshaft. • We provided proof that the monoharmonic model fits basic data well. We have previously described a novel crankshaft support system that can be used when measuring and testing crankshafts. Here, we extend our studies on this system using mathematical models (basic polyharmonic, spline-based polyharmonic, and monoharmonic functions) to identify the optimal conditions for supporting geometric measurements of large crankshafts. The obtained results improved the accuracy of this system and provided alternative solutions by minimizing shaft deflection during measurements. It was proposed and confirmed that variable reaction forces in flexible crankshaft supports can be mapped using a monoharmonic model with a good fit to the source data. At various selected crankshaft positions, finite element analysis software was used to determine the reaction forces, for which three different mathematical models were tested. The usefulness of each individual model was discussed in terms of the complexity and accuracy of mapping the source values. [ABSTRACT FROM AUTHOR]