FreeScan Trak Nova | Wireless Industrial Metrology

The Shining 3D FreeScan Trak Nova is a wireless, metrology-grade 3D scanning system designed for large-scale industrial inspection without physical markers. By integratingpatented Video Photogrammetry (VPG), it establishes global coordinates via real-time video capture, achieving a volumetric accuracy of0.046 + 0.012 mm/m. Engineered for the Australian shop floor, the system features a massive2.6 x 2.2 m field of view and50 blue laser lines, capturing 6.14 million points per second. It is verified underVDI/VDE 2634 Part 3 andISO 10360 standards, making it the primary solution for inspecting heavy machinery, aircraft components, and automotive assemblies where cable-free mobility is essential.

Information Gain: Technical Advantage Analysis

Eliminating Target Application Bottlenecks

Traditional large-scale scanning requires hours of manual target placement to maintain volumetric integrity. The FreeScan Trak Nova’s VPG module removes this requirement by using a calibration rod and video tracking to verify the global coordinate system. In a laboratory-to-shop-floor transition, this translates to a 70% reduction in setup time for components exceeding three metres. This is not merely a convenience; it is a critical shift in throughput for facilities managing high-volume refurbishment or aerospace maintenance cycles.

Dynamic Tracking in Unstable Environments

Vibrations from nearby heavy machinery often compromise CMM and standard laser scanner data. The FreeScan Trak Nova utilizes real-time dynamic tracking to lock the spatial relationship between the tracker and the part. If the floor shifts or the object is repositioned, the coordinate system remains absolute. This allows for metrology-grade precision in active manufacturing zones rather than isolated, temperature-controlled labs

Wireless Shop-Floor Synchronisation

Operating on a dedicated Wi-Fi 6 protocol, the system maintains a high frame rate and stable data transfer without the hazards of fiber optic tethering. The dual-computing modules within the UE Nova and TE Nova units handle the primary data processing locally, ensuring that the live mesh generation is lag-free even at the peak 6,140,000 points/s capture rate.

Why the FreeScan Trak Nova is Essential for Large-Scale Industrial Applications

Large-scale industrial scanning requires a balance of volumetric accuracy, mobility, and speed. The FreeScan Trak Nova addresses these through several critical technical advantages:

• Markerless Global Accuracy: Utilizing patented Video Photogrammetry (VPG), the system establishes global coordinates without the need for manual marker placement, significantly reducing setup time for large components like aircraft wings or industrial agitators.

• Wireless Shop-Floor Mobility: Integrated wireless and computing modules allow operators to move freely around large structures up to 3.5 metres from the tracker without cable interference or data lag.

• Dynamic Tracking: The system maintains high accuracy even in unstable shop-floor environments. If the part or the tracker moves, the dynamic tracking ensures the coordinate system remains locked, preventing data misalignment.

• Massive Field of View (FOV): With a FOV of up to 2.6 x 2.2 m, the scanner captures large surface areas rapidly, reducing the number of individual scans and data stitching requirements.

Key Technical Features

Patented Video Photogrammetry (VPG)

Traditional photogrammetry requires the application of coded markers to establish a coordinate system. The FreeScan Trak Nova uses VPG technology and a calibration rod to verify markers via real-time video capture. This ensures consistent volumetric accuracy (0.046 + 0.012 mm/m) across large volumes without the labour-intensive process of applying and removing markers.

High-Density Laser Scanning

The system features 50 blue laser lines for high-speed scanning and a dedicated single-line mode for deep pockets and hole measurements. With a scan speed of up to 6,140,000 points per second and a resolution of 0.01 mm, it captures intricate details of complex geometry while maintaining the throughput required for industrial manufacturing.

Wireless Freedom and Swappable Power

The scanner and tracker operate via a Wi-Fi 6 connection, ensuring stable data transfer at high frame rates. Dual swappable batteries allow for uninterrupted workflows; the scanner (UE Nova) provides approximately one hour of continuous use per battery, while the tracker (TE Nova) lasts up to 2.5 hours.

Metrology-Grade Certification

Accuracy is verified according to VDI/VDE 2634 Part 3 and ISO 10360 standards. All calibrations are performed in an ISO/IEC 17025 accredited laboratory, ensuring full traceability for rigorous quality assurance protocols in regulated industries like civil aviation and heavy energy.

Industrial Case Studies and Applications

Heavy Machinery and Refurbishment In heavy equipment refurbishment, companies like Steelstruct use the Trak Nova to inspect wear and deformation on massive components. The markerless capability allows for immediate scanning of excavators and bulldozers, providing the data needed for simulation analysis and precision repair without the downtime associated with traditional measurement methods.

Aerospace and Energy Research at FH Aachen University utilises the Trak Nova for ultra-accurate 3D modelling of electric aircraft. The system's ability to maintain precision over large spans is critical for aerodynamic analysis and structural integrity checks. Similarly, in the energy sector, it is used for the inspection of large industrial agitator components, where capturing complex curvatures with high resolution is paramount.

Automotive Quality Control The Trak Nova excels in the automotive sector for both sheet-metal inspection and full-vehicle scanning. Facilities like Liuzhou Yinrui leverage the system to streamline the inspection of large automotive parts, reducing the bottleneck typically found in CMM (Coordinate Measuring Machine) rooms by bringing metrology-grade precision directly to the production line.