Objective
This graduation project covered the full reverse-engineering cycle of a large DN1300 shut-off valve. It pursued two goals: preparing a complete set of engineering documentation for import substitution and modernizing the valve by integrating an automatic control system.
Scope of Work
The work started with 3D scanning of a used ARMATURY Group valve. Initial measurements taken with a Scanform L5 scanner proved insufficient for the sealing surfaces: only 35.6% of points were within the ±0.1 mm tolerance. After a repeat scan of the internal geometry with a KSCAN-Magic scanner, 84.1% of points fell within tolerance, making the data suitable for further engineering work.
Point clouds were processed in Geomagic Design X, where the project focused not only on surface reconstruction but also on analyzing the eccentric geometry characteristic of this valve type. Theoretical values of the first eccentricity were calculated using D. F. Gurevich's methodology and compared with the scan results. Because Geomagic Design X cannot transfer editable parametric models directly into KOMPAS-3D, every model tree was rebuilt manually to obtain fully editable production models instead of imported "dead" solids.
In parallel, a full set of engineering calculations was performed: static and dynamic loads, friction torques, hydrodynamic torque, and safety-system parameters. The calculations showed that the selected domestic drive and gearbox exceeded the mass of the original Auma units by 2.5 times, which ruled out a direct replacement without redesigning the emergency-closing linkage. The safety system with lever, counterweight, electromagnet, and damper was also verified, including a required holding force of 3848 N. The automation concept was then developed around Siemens components because of integration requirements and the lack of locally available positioners comparable to the Siemens SIPART PS2 in accuracy, speed, and diagnostics.
Result
The final result was not just a set of drawings but a complete engineering solution: an accurate digital twin, verified calculations, a full documentation package, and an automation concept suitable for further implementation.
Software used: Geomagic Design X, Geomagic Control X, KOMPAS-3D v20, Siemens TIA Portal & WinCC