Automated Processing and Deviation Analysis of 3D Pipeline Point Clouds Based on Geometric Features

To meet the strict non-contact measurement requirements for the assembly of aircraft engine pipelines and to overcome the limitations of the traditional three-dimensional laser scanning workflow, this study proposes an automated pipeline point cloud processing and deviation analysis framework. Through a standardized three-dimensional laser scanning procedure, high-resolution pipeline point clouds are obtained and preprocessed. Based on the geometric characteristics of the pipeline, automated algorithms for point cloud feature segmentation, axis extraction, and model registration are developed. Particularly, the three-dimensional extended Douglas–Peucker (DP) algorithm is introduced to achieve efficient point cloud downsampling while retaining necessary geometric and structural features. These algorithms are fully integrated into a unified software platform, supporting one-click operation, and can automatically analyze and obtain five key types of pipeline deviations: angular deviation, radial deviation, axial deviation, roundness error, and diameter error. The platform also provides intuitive visualization effects and comprehensive report generation functions to facilitate quantitative inspection and analysis. Test results show that the proposed method significantly improves the processing efficiency and measurement reliability of complex pipeline systems. The developed framework provides a powerful practical solution for the automated geometric inspection of aircraft engine pipelines and lays a solid foundation for subsequent quality assessment tasks.