Digital Twin of an Industrial Dust Extractor
At Vertex Access, we thrive on challenges that push the boundaries of drone technology. This project involved creating a high resolution 3D photogrammetry model of a large, complex steel dust extractor situated on an industrial roof. The result is a precise "digital twin" that revolutionizes how the asset is inspected, managed, and maintained.
Scaled 3D Photogrammetry Mesh of Asset
Detailed Asset Survey & Inspection on an Inaccessible Roof
Our client required a comprehensive and dimensionally accurate 3D model of a historic dust extractor unit. The primary goal was to create a digital asset that would allow for detailed remote inspections, accurate maintenance planning, and a permanent record of the asset's condition, without the need for high-risk manual access.
The Challenges
Creating a perfect 3D model is never simple, and this project presented a unique combination of complex obstacles:
Limited Roof Access: The roof had significant structural limitations and very few designated walkways. This made a traditional roof-based drone launch and close-quarters flight impossible. The entire mission had to be planned and executed from ground level, demanding exceptional piloting skill and flight planning.
Intricate Geometry: Steel structures, especially those with fine details like pipes, bolts, and grating, are notoriously difficult to capture accurately with photogrammetry. The risk of creating digital "noise" or incomplete geometry was high.
Harsh Lighting Conditions: The project took place on a day with bright, direct sunlight. This created extreme contrast between brightly lit surfaces and deep shadows. For photogrammetry, which relies on consistent visual data, these constantly changing lighting conditions and exposure values presented a significant data-capturing challenge.
Over 5,000 High Resolution Aerial Images Collected to Create a Photorealistic Mesh
Meticulous Planning and Advanced Technology
Our team engineered a solution that directly addressed each challenge:
Strategic Flight Planning: We developed a multi-layered flight plan executed entirely from the ground. This involved a combination of automated orbital flights at various altitudes and manual, targeted flights to capture intricate details and areas in deep shadow. This ensured 100% data coverage of the asset.
High-Resolution Data Capture: Using state-of-the-art drones equipped with high-resolution cameras, we were able to capture the minute details of the steelwork. By shooting an extensive number of overlapping high-resolution images, our processing software could accurately reconstruct even the most complex geometric elements.
Advanced Data Processing: The high-resolution images were imported into our processing software. The software automatically reconstructed the asset using the geo-located images, while our specialists fine-tuned the parameters to neutralise the harsh shadows and highlights. This synergy between automated technology and expert oversight produced a clean, evenly lit, and stunningly accurate 3D model.
The final step was to upload this powerful digital twin to a web-based viewing platform. This provides the client with on-demand access from anywhere in the world.
The Outcome: An Interactive Tool for Modern Asset Management
The deliverable was more than just a 3D model; it was a comprehensive, interactive asset management tool. Within the online viewer, the client can:
Conduct Virtual Inspections: Pan, zoom, and rotate the model to inspect any component from any angle.
Tag Defects and Observations: Upload new site-specific inspection photos and tag them to their exact location on the 3D model, creating a visual and intuitive record of defects or areas of interest.
Take Accurate Measurements: Pull precise measurements for dimensions, clearances, or material quantities directly from the model for effective project planning.
3D Model Hosted Online to Enable Collaborative Inspection, Annotations & Measurements
This project demonstrates how advanced drone photogrammetry, when paired with expert execution, can overcome significant on-site challenges. Vertex Access provided a solution that not only enhanced safety by eliminating work-at-height but also delivered a cost-effective, highly detailed, and invaluable digital tool for the asset's entire lifecycle.
