Manufacturing is the backbone of modern industry, producing everything from automobiles to wind turbines and solar panels. However, many manufacturing processes rely on complex gas and vacuum systems, where leaks can lead to inefficiencies, product defects, and even safety hazards.
Leaks in manufacturing facilities aren’t an uncommon problem. With the scale of manufacturing plants and the amount of places where leaks can occur, there are bound to be problems occurring at some point. Problems such as:
- Defective Products – Poor sealing or vacuum leaks in processes like wind turbine blade manufacturing can result in cracks and structural failures.
- Energy Waste – Leaks in compressed air and nitrogen systems drive up operational costs.
- Safety Risks – Undetected gas leaks can create hazardous work environments, leading to potential accidents.
Now, to tackle leak detection in manufacturing, plant management will often opt for the cheaper methods of detecting, but these methods are often unreliable, slow and even potentially dangerous. Methods such as:
- Soap and Water Tests – These are slow, labor-intensive, and ineffective for large-scale inspections.
- Handheld Gas Detectors – This method requires technicians to be close to leaks, making detection in high or confined spaces difficult and potentially dangerous.
- Vacuum Decay Testing – While this method does work for some applications, it lacks real-time visualisation and requires stopping production for testing, leading to unnecessary downtime.
Introducing a New Method for Leak Detection in Manufacturing
This is why, a new method is being seen more and more in the manufacturing industry. And this method is acoustic imaging…
You may be wondering, how is acoustic imaging going to be applied to leak detection in manufacturing?
Well, when a pipe leaks, it is often through a tiny hole, this combined with the high pressure of gas inside the pipe creates an extremely high pitched sound that is completely inaudible to humans. For reference, the average human can hear up to around 16 KHz… These leaks are making sound at up to 70 – 80 KHz. That’s really high pitched.
This is where the CRY8124 comes in. This is a handheld acoustic camera that is able to hear and visualise these ultrasonic sounds into a heatmap displayed over the image of what you’re looking at.
Case Studies: How the CRY8124 Has Been Applied for Leak Detection in Manufacturing
The CRY8124 was deployed to detect leaks in thermal exhaust and acid-alkali exhaust systems. Traditional detection methods were ineffective, and manual inspections were too time-consuming. With the CRY8124, technicians quickly identified negative pressure leaks, preventing system inefficiencies.
During the vacuum infusion molding process, undetected leaks led to poor resin impregnation, causing structural defects in turbine blades. The CRY8124 provided precise, real-time leak detection, giving plant managers the data they needed to apply proper vacuum sealing and preventing future cracks and deformations.
Sealing issues in vehicles were previously tested using traditional methods that required extensive setup and space. The CRY8124 allowed manufacturers to conduct ultrasonic sealing tests by placing sound sources inside the vehicle, reducing installation costs and increasing the speed of inspections dramatically.
In factories relying on compressed air and nitrogen, leaks were often overlooked due to the inefficiency of manual inspections. The CRY8124 enabled technicians to scan entire systems quickly, reducing energy waste and preventing costly leaks from going unnoticed.
What makes the CRY8124 Unique for Leak Detection in Manufacturing?
Real Time Acoustic Imaging – The CRY8124 can instantly visualise leak locations with high resolution imaging, saving you valuable time.
Dual Thermal and Acoustic Imaging: The CRY 8124 combines thermal imaging with acoustic detection, allowing simultaneous visuals of thermal and ultrasonic data. This is especially useful in hot environments, where identifying temperature patterns aids in troubleshooting.
Operating up to 10 hours with replaceable batteries, the CRY 8124 is designed for continuous use in large facilities. Wireless data transfer and advanced reporting software simplify documentation, allowing for seamless sharing of inspection data.
Long-Range Detection: Identifies leaks from a safe distance without the need for direct contact.
Saving you time and money.
One of the best features of the CRY 8124 is it’s reporting capabilities. This camera is able to produce a report which would typically take hours, in just a few minutes. With information on the the type of leak, the DB, the location and even more. All presented in an easy-to-read PDF with images of the leak included too.
So not only are you saving time on detecting the leak, but you’re also saving time on reporting on the leak. Altogether, you can do what could be a full days work in mere minutes with this camera.
Now imagine spreading this over a huge plant? You could be saving hundreds of thousands of pounds in working hours and when working with leak detection in manufacturing.
To find out more check out the CRY8124 or speak with our team
