Case Study: Tackling Compressed Air Leaks in Automotive Parts Manufacturing with Acoustic Imaging

Facing rising energy costs and increasing pressure to meet CO₂ regulations, an automotive parts manufacturer explored the FLIR Si124 acoustic imaging camera for compressed air leak detection. This case study demonstrates how the tool streamlined inspections, uncovered hidden leaks and enhanced maintenance efficiency within a noisy industrial environment.

Used to power production machinery like pneumatic tools, vacuum generators and actuators, compressed air is a critical commodity in the automotive parts manufacturing industry. With complex piping systems spread across large facilities, compressed air leaks are both common and costly. At one US automotive parts factory, the maintenance team was increasingly concerned about rising energy consumption, pressure drops and frequent disruptions caused by undiagnosed leaks. Traditional detection methods had proved to be time-consuming, inconsistent and difficult to use effectively in vast production areas filled with noise, making a more efficient inspection method necessary to keep operations running smoothly and reduce unnecessary energy loss and CO₂ emissions.

Testing the FLIR Si-series acoustic imaging camera

To address these issues, the factory's manufacturing engineer initiated a test of a FLIR Si-Series acoustic imaging camera. The goal was to evaluate whether the device could offer a faster, more reliable way to detect compressed air leaks during regular inspections without interrupting production.

The testing was carried out over a four-week period and focused on critical areas such as assembly lines powered by pneumatic tools, overhead compressed air lines and maintenance zones known for frequent small leaks. Although the constant air exhaust from actuators during production creates significant turbulence and noise – making it challenging to detect leaks inside the machines – the inspections were successfully carried out also during normal operating hours to reflect real-world conditions.

The results

The acoustic camera instantly identified compressed air leaks and produced clear, real-time acoustic images. This made it easy to pinpoint leaks, even those hidden in overhead pipes or amidst dense machinery. The array of sensitive MEMS microphones and advanced sound processing capabilities effectively isolated even minute leak sounds from background noise. The intuitive, easy to use design required minimal training, allowing for immediate use and efficient inspections.