SOFTWARE IMPLEMENTATION OF AN AUTOMATED CALIBRATION SYSTEM

Abstract

The paper presents the software implementation of an automated calibration system for horizontal steel tanks based on laser 3D scanning data and a geometric calibration method. Accurate calibration of storage tanks is a critical task in industrial metrology, as it directly affects the reliability of commercial accounting of liquids and compliance with regulatory requirements. Traditional geometric calibration methods are often limited by simplified models and local linear measurements, which do not fully reflect real geometric deviations, deformations, or manufacturing tolerances of tanks in operation.

The proposed system provides a complete automated workflow for processing measurement data, starting from the import of three-dimensional point clouds and ending with the generation of sub-millimeter calibration tables and standardized reporting documentation. The software architecture is designed using a modular approach, ensuring scalability, flexibility, and ease of maintenance. The system is implemented in Python and integrates open-source scientific and engineering libraries for numerical computation, 3D data processing, and document generation.

Special attention is paid to the development of calculation algorithms that comply with the requirements of DSTU 7475:2016, with adaptations for the use of dense three-dimensional point clouds. A combined segmentation approach is applied to identify the structural elements of the tank, including the cylindrical body and end caps. This approach combines the RANSAC method for surface fitting with DBSCAN clustering, enabling robust segmentation even in the presence of noise, uneven point density, and local geometric distortions.

The system automatically determines the geometric parameters of the tank and calculates its volume for each filling level with a resolution of 1 mm. The results are presented in the form of calibration tables generated in Microsoft Excel format and comprehensive calibration reports created in Microsoft Word format, fully compliant with metrological standards. A graphical user interface based on PyQt5 ensures intuitive interaction with the system and minimizes the influence of human error.

The developed software solution enhances the level of automation, accuracy, and reproducibility of tank calibration procedures and can be effectively applied in industrial metrology practice for the calibration of horizontal steel tanks using modern 3D measurement technologies.