3D Cable Surface Scanning for Deformation Tracking Under Load

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Solution Overview

Problem

Existing methods for tracking deformations in high voltage and medium voltage cables and cable components under mechanical loads are limited in versatility and accuracy, particularly when using cameras, film, and manual measurements, and do not effectively capture 3D deformations.

Innovation Solution

A method utilizing a 3D surface scanner to capture and compare sets of 3D surface geometry measurement data at different points in time to detect and monitor deformations in cables and components, employing laser scanners, structured light scanners, or lidar-based systems, and avoiding the use of talc spray by using blue laser technology, sticky or magnetic markers, or external cameras with self-positioning markers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If cameras, film, and manual measurements are used to track deformations, then the measurement process is simple and accessible, but the versatility and measurement precision are insufficient

Engineering Contradiction:

Improvedeformation measurement precisionVSAvoidmeasurement system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual measurement systems with a 3D laser scanning system that uses optical fields to capture surface geometry. The laser scanner emits laser beams to measure distance to the surface, creating detailed 3D point clouds that automatically record deformation without manual intervention, thereby improving precision while managing complexity through automation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates digital 3D copies (point clouds) of the cable surface geometry at different time points. These digital models serve as accurate replicas that can be stored, compared, and analyzed without requiring physical contact or repeated manual measurements, enabling precise deformation tracking through digital comparison.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If 3D surface scanning is implemented to accurately capture deformations, then the measurement precision and versatility improve, but the device complexity and measurement time increase

Engineering Contradiction:

Improvemeasurement versatilityVSAvoidmeasurement time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent implements periodic measurements by capturing 3D surface geometry at multiple discrete time points (t1, t2, t3, etc.). The scanner takes measurements at regular intervals during deformation processes, allowing verification of deformation progression while limiting total measurement time through scheduled sampling rather than continuous monitoring.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent performs preliminary scanning to establish baseline 3D geometry before deformation occurs. This initial 3D model serves as a reference for subsequent comparisons, allowing the system to quickly identify changes without requiring complex real-time analysis during the actual deformation process.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional scanning methods are used, then the device complexity is lower, but the ability to detect and monitor deformations over time is insufficient

Engineering Contradiction:

Improvedeformation detection reliabilityVSAvoidscanning system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a feedback mechanism by comparing 3D surface geometry captured at different time points and automatically identifying changes. The system processes the point cloud data to detect deformations, provides feedback on measured changes, and can trigger alerts when deformation exceeds thresholds, thereby improving reliability through automated monitoring and decision support.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Accurately tracks and monitors deformations in cables and components over time, providing a quality report with go/no-go evaluations and identifying critical changes, enhancing operational safety and maintenance efficiency.

Implementation Method 1

measuring distance to the surface over the area of the surface by sequentially measuring a plurality of sub-areas of the area of the surface with a laser scanner

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS12487189B2Laser scanning of cable and cable accessory components subjected to mechanical loads and elastic or inelastic deformation

Publication Date: 2025.12.02 NEXANS SA

AI summary

A method for detecting deformations of high voltage and/or medium voltage cables and/or cable components, include at a first point of time, capturing and storing (302) a first set of 3-dimensional, 3D, surface geometry measurement data of an area of interest of a surface of the cable or cable component. The method also incudes, at a second point of time, capturing and storing (304) a second set of 3-dimensional, 3D, surface geometry measurement data of an area of interest of a surface of the cable or cable component by moving a 3D surface scanner about the cable over the area of interest. The first and second sets of captured 3D surface geometry measurement data is compared to determine changes that have occurred in the cables or cable components between the first and second points of time, where changes indicate a deformation of the cable or cable component.