Analytical Determination of Geometric Parameters of the Rotary Kiln by Novel Approach of TLS Point Cloud Segmentation

This research focused on determining a rotary kiln’s geometric parameters in a non-traditional geodetic way—by deriving them from a survey realized by a terrestrial laser scanner (TLS). The point cloud obtained by TLS measurement was processed to derive the longitudinal axis of the RK. Subsequently, the carrier tires’ geometric parameters and shell of the RK during the shutdown were derived. Manual point cloud selection (segmentation) is the base method for removing unnecessary points. This method is slow but precise and controllable. The proposed analytical solution is based on calculating the distance from each point to the RK’s nominal axis (local radius). Iteration using a histogram function was repeatedly applied to detect points with the same or similar radiuses. The most numerous intervals of points were selected and stored in separate files. In the comparison, we present the conformity of analytically and manually obtained files and derived geometric values of the RK-radiuses’ spatial parameters and coordinates of the carrier tires’ centers. The horizontal (X and Y directions) and vertical (Z-direction) of root–mean–square deviation (RMSD) values are up to 2 mm. RMSD of the fitting of cylinders is also up to 2 mm. The center of the carrier tires defines the longitudinal axis of the RK. Analytical segmentation of the points was repeated on the remaining point cloud for the selection of the points on the outer shell of the RK. Deformation analysis of the shell of the RK was performed using a cylinder with a nominal radius. Manually and analytically processed point clouds were investigated and mutually compared. The calculated RMSD value is up to 2 mm. Parallel cuts situated perpendicularly to the axis of the RK were created. Analysis of ovality (flattening) of the shell was performed. Additionally, we also present the effect of gradually decreasing density (number) of points on the carrier tires for their center derivation.