Visualising invisible losses .

The growing role of acoustic imaging technology in automotive manufacturing, where compressed air inefficiency, pneumatic instability, and leaks can quietly undermine production performance and energy efficiency, as well as process consistency.

Modern vehicle production relies on tightly synchronised operations. From robotic welding and automated paint systems to CNC machining and final assembly, every stage depends on a reliable and efficient compressed air supply. Yet while electrical or mechanical faults are often immediately visible, compressed air losses can remain undetected.

Industry estimates suggest that manufacturing facilities may lose between 20% and 30% of compressed air through leakage. In automotive plants featuring extensive pneumatic systems and large-scale distribution networks, even minor leaks can translate into significant energy waste and inefficient equipment, while operational costs are also likely to increase.

Other issues like pressure instability are also detrimental, affecting factors like welding consistency, paint atomisation quality, torque repeatability, vacuum gripping reliability, and equipment cycle stability. With many problems developing gradually, maintenance teams often face reactive troubleshooting rather than structured and more cost-efficient prevention.

Acoustic imaging changes this dynamic by converting high-frequency sound into clear visual information, allowing maintenance personnel to identify leaks and abnormal sound sources quickly, even in noisy production environments.

Unlike traditional tools such as ultrasonic testers and leak detectors that typically rely on single microphones and operator interpretation, HIKMICRO AI Series acoustic imaging cameras offer up to 136 low-noise MEMS microphones and adjustable bandwidth technology ranging from 2 to 96 kHz. The result is fast, accurate localisation of compressed air leaks during live production.

Designed for industrial maintenance applications, the HIKMICRO AI Series can detect leaks as small as 0.0047 l/min at 6 bar pressure from 0.5 m distance. Real-time visualisation on a 4.3” touchscreen allows users to pinpoint problems immediately, while integrated analysis software calculates estimated leak rate, leak cost, and energy impact. Voice, text, QR code, and image annotations further support inspection traceability and workflow efficiency.

Built for automotive production.
Automotive manufacturing facilities present unique maintenance challenges. In robotic welding workshops, fast-moving hose assemblies and difficult-to-access pneumatic systems make leak detection difficult during active production. Acoustic imaging enables maintenance teams to locate leaks without stopping robotic operations, helping maintain take time and reduce unplanned downtime.

In paint shops, where any compressed air instability can directly impact coating quality and energy efficiency, acoustic imaging supports structured air audit programs by identifying leaks during operation. Similarly, final assembly lines benefit from rapid inspection of pneumatic tools and vacuum systems, helping prevent gradual performance drift and repeatability issues.

HIKMICRO AI Series acoustic imaging cameras can also underpin plant-wide maintenance strategies. Compressor stations, centralised utility systems, machining workshops, and casting/molding operations can all benefit from faster leak localisation and earlier identification of abnormal sound sources before small issues escalate into production stoppages.

Results
Compared with conventional leak detection methods, acoustic imaging can reduce inspection times by up to 90%. Furthermore, long-range operation up to approximately 150 m improves safety by enabling inspections from distance in hazardous or hard-to-access areas.

“Automotive manufacturing is fundamentally built on repeatable and efficient processes,” says Stefan Li, Overseas Market Director at HIKMICRO. “Acoustic imaging gives maintenance teams visibility into problems that traditionally remain hidden until they disrupt production. By transforming sound into actionable visual information, manufacturers can move from reactive maintenance to predictive and data-driven operational management.”

With automotive manufacturers continuing to scrutinise energy optimisation, uptime improvements, and predictive maintenance strategies, acoustic imaging is fast emerging as an increasingly valuable tool for improving visibility across critical pneumatic infrastructure.

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@hikmicro #Automotive #PAuto

Acoustic imaging in hazardous locations.

Reliable detection of pressurised gas leaks, mechanical faults, and partial discharge in explosive vapor and dust environments.

An IECEx certified version of FLIR's Si2x, an advanced industrial acoustic imaging camera purpose-built for professional inspectors who need fast, accurate compressed air and gas leak detection in hazardous environments has been announced. Now certified to both ATEX and IECEx standards, the FLIR Si2x is engineered for safe operation in explosive atmospheres while delivering industry-leading performance and usability.

Compressed air and pressurized gas leaks, mechanical faults and partial discharge are all common and costly issues in industrial sectors such as chemical processing, oil & gas, and pharmaceuticals, where safety and reliability are paramount. The FLIR Si2x empowers maintenance professionals to identify and quantify these issues with unmatched precision and speed, even in environments where traditional tools are not permitted.

Key features of the FLIR Si2x-Series include:

• ATEX and IECEx Certified: The Si2x is fully certified for use in hazardous locations, enabling safe and compliant inspections in explosive atmospheres.
• Best-Performing Acoustic Detection: A highly sensitive microphone array delivers pinpoint accuracy for fault detection up to 200 meters away, making it ideal for high ceilings, hard-to-reach assets, and noisy plant floors.
• 
  On-Device Quantification: Instantly view leak size and estimated annual cost, as well as partial discharge severity, enabling prioritization of repairs and fast ROI. Data can be used to support ESG and sustainability reporting initiatives.
• Bandpass Filtering: Customizable bandpass filter allows users to target specific ultrasonic frequencies, cutting through noisy environments to detect the most subtle leaks with clarity.
• High-resolution visual documentation: Integrated 12 MP visual camera with 8× digital zoom and built-in LED lighting helps users capture detailed contextual images for reports and maintenance workflows.
• Safe and Easy to Use with Minimal Training: Built for demanding field conditions, the Si2x is lightweight, compact, and easily operated with one hand. A large touch-screen interface and intuitive UI reduce training time and increase inspection throughput.
• Seamless Data Transfer and Reporting: Use Wi-Fi, USB, or the new secure data transfer cable to move images and analytics to FLIR Thermal Studio or FLIR Acoustic Viewer. Support for Over-The-Air (OTA) firmware updates ensures continuous improvement and compatibility.

“The Si2x is a breakthrough for inspectors who need high-performance acoustic imaging in the most safety-critical environments,” said Darrell Taylor, Global Acoustic Business Development Manager at FLIR. “It empowers teams to work safely and efficiently, detect leaks faster, and reduce energy waste — all while meeting the industry’s most demanding standards. With its rugged design, precision performance, and intuitive operation, the Si2x is built to handle real-world challenges.”

Two versions of the Si2x are available: the Si2x-LD, designed for detecting pressurized gas leaks and mechanical faults, and the Si2x-Pro, which includes all the capabilities of the LD model plus the ability to identify partial discharge. All other features remain the same.

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Air leak detection.

New acoustic Imaging Camera helps professional inspectors locate smaller compressed air leaks faster and accurately.

The Si1-LD, an industrial acoustic imaging camera that brings faster and more accurate compressed air leak detection to those operating on a modest condition monitoring budget has been introduced by FLIR. The Si1-LD offers improved detection and quantification capabilities in comparison with the existing FLIR Si124-LD Plus, along with a higher upper limit frequency range.

Compressed air systems typically lose 25–30% of their air to leaks, resulting in proportionally higher energy bills, costly unplanned production stoppages, shorter compressor operating life, the need to purchase extra compressor capacity, and increased maintenance expenses for the additional equipment.

Leveraging the advantages of ultrasonic technology, the new FLIR Si1-LD pinpoints leaks with enhanced imaging sensitivity at an affordable price. It offers a number of stand-out capabilities and features:

• An array of 96 microphones (2–100 kHz) facilitates the automatic detection, location, and measurement of compressed air and vacuum leaks from a safe distance of up to 130 m. Support comes from a 12 MP color camera with 8× digital zoom and LED lamp, facilitating the easy capture of visual details.
• Bandpass filtering allows inspectors to effectively tune out any confusing and/or incorrect sources of ultrasound without manual tuning. Ideal for challenging leak detection applications where user input is advantageous, the inspector simply uses the bandpass filter to undertake manual tuning of the required frequency range and clearly displays the source of interest on very rare occasions when needed.
• Single-handed operation of the lightweight, compact FLIR Si1-LD ultrasonic imager and industry-leading AI makes for an easy-to-use device with minimal training perfect for fast-paced inspections across large facilities.
• The touch-screen interface displays high-resolution images for easy issue identification with real-time, on-device quantification in terms of leak volume flow rate and leak cost per year. Users can leverage this data to prioritize repairs. The data is also suitable for inclusion in sustainability reports as an indication of energy reduction initiatives.
• Wireless data transfer ensures seamless reporting/analytics options, using either the online FLIR Acoustic Viewer or offline FLIR Thermal Studio effortless data backup and organizational team sharing, while also providing the backbone for Over The Air (OTA) firmware updates. The software gives users the ability to create reports through pre-built or fully customizable templates.

“Many manufacturing and process plants are seeing their energy bills creep up through leaky compressed air systems, increasing OPEX [operational expenditure] and eroding margins,” said Darrell Taylor, Global Acoustic Business Development Manager at FLIR. “If you want to find leaks quickly and easily with minimal technician training, our new Si1-LD industrial acoustic imaging camera provides a fast and precise solution that supports sustainable manufacturing. As well as reduced energy consumption, the new device helps you save on maintenance, repair, operation, and capital/OPEX costs all while enhancing worker safety. With its minimum detected leak rate [MDLR] of 0.01 L/min at 2.5 m, our Si1-LD offers the market’s best combination of performance and ease-of-use in its price point.”

The new acoustic imaging camera comes with two batteries, additional battery cover, battery charger, camera neck strap, hard case, USB memory stick, access to free versions of online & offline acoustic analysis and reporting software, and two-year warranty. A new accessory is the data transfer cable. This handy cable allows users to connect directly from the camera to a PC/laptop, supporting easy file access at organizations that forbid the use of WiFi and USB drives. Users can upload their acoustic images into FLIR Thermal Studio software or the FLIR Acoustic Viewer

Two versions of the Si1-LD are available, with and without WiFi. All other features are the same.

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Discounted acoustic camera.

In 2021, FLIR Teledyne launched the FLIR Si124-LD acoustic imaging camera. It represented state of the art technology and 4 years later it is still seen as a high-end analytical tool with an amazing array of advanced features and benefits.

So what is an acoustic camera and what are they used for? Acoustic cameras contain a high number of highly sensitive microphones capable of detecting sounds well out of the audible range of the human ear. The sounds picked up by the microphones are translated into signals on a screen creating a visual image of the environment being analysed.

Acoustic cameras can be used to identify several common problems that often go unnoticed in industry such as leaks in gaseous systems. Sadly, many problems only manifest themselves when catastrophic failure occurs resulting in unscheduled maintenance, production stoppages and issues with customer confidence.

The majority of industrial complexes utilize compressed air for a multitude of operations. The air is delivered via a network of pipes and air lines, containing elbow joints, reducers, condensers all with the potential of leaking the compressed air. The FLIR Si-124-LD Plus acoustic camera from FLIR can detect tiny amounts of air from such joints which in themselves may not be large but when multiplied by the number of joints can be very significant.

Following the success of the FLIR 124-LD acoustic camera, earlier this year FLIR introduced a new state of the art acoustic camera entitled the FLIR Si2-LD, containing several new advanced features. As a result, FLIR are now offering the FLIR 124-LD camera at a discounted price of €8799 (£7399stg) before tax, while stocks last.

With an impressive technical specification, the camera makes an ideal addition in the fight against unscheduled maintenance and leak detection. Containing 124 microphones, the Si124-LD produces a precise acoustic image that visually conveys ultrasonic information even in environments with loud background noises.

Working in real time, the acoustic image is transposed to the screen on top of a visual image taken by the onboard digital camera allowing the operator to accurately pinpoint the source of the problem. The operator then utilises the FLIR Si124-LD Acoustic Camera Viewer cloud service to save images for either deeper analysis or reporting.

The camera allows the operator to take readings at up to 100 metres, thus overcoming the problem of in-accessible areas. At close ranges, the improved sensitivity of the new camera really comes into its own; with an operating range from 2kHz to 65kHz, the high sensitivity can detect the tiniest of leaks.

A further feature of the Si124-LD Acoustic Camera is the lightweight nature of the equipment. It has been specifically designed to be held in one hand, allowing the operator to safely access elevated platforms whilst holding handrails, always ensuring safety.

In terms of air leaks, not only is the problem clearly located, by programming various variables on the camera it automatically calculates the annual financial loss caused by the air leak. This figure is displayed on the screen, providing an immediate quantifiable monetary value.

In these challenging times when companies are constantly looking to improve operating efficiency the Si124 -LD Acoustic Camera can prove to be an extremely valuable tool in detecting and quantifying plant inefficiencies and financial penalties affecting the all-important bottom line.

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Which one of 18 million ways to detect air leak?

Teledyne's Daryll Taylor helps in looking for advancements on the soapy water technique.

Daryll Taylor

The other day I performed a Google search for ‘How to detect an air leak’. Not surprisingly it came up with millions of results, over 18 million in fact.

Whether solving the problem in a commercial establishment or a domestic home environment, the majority of search results pointed to one solution. Namely, soapy water!

Before we all ridicule the idea as belonging to a bygone era, take a vehicle with a slow puncture to a tyre fitting depot and the chances are they remove the wheel and spin it in water to determine the leak. It’s a simple time proven method for determining leaks from pressurised systems.

But of course, not all equipment can be placed in soapy water. What if a system is known to be losing pressure and yet the lines carrying the compressed air from the source are located 10 metres above the ground, and dismantling the system is out of the question? Thankfully there is a fast and effective solution to hand.

Each time air or indeed any gas, leaks from a pressured system there is an associated sound. If the leak is significant, it can be audible to the human ear and therefore easily identified and rectified accordingly. However, most leaks in high pressure systems are extremely small and are out of the range of a human ear.

Think about a pressured air system on a large factory delivering compressed air from a bank of compressors to various stages of production throughout the manufacturing process. The chances are there are hundreds if not thousands of connections in the form of joints, reducers, valves, elbows, condensers etc. Each of these has the potential to leak small amounts of air, reducing the pressure of the system.

One leak might make very little difference but multiply this by the number of potential leaking joints and efficiency can be significantly compromised. The compressor will seek to compensate for any pressure loss by simply working harder. However, as any engineer will know, compressors can be expensive to operate in terms of energy and therefore will certainly increase an operators energy consumption.

With electricity costs being so much higher in Europe due to geopolitical factors in recent years, most companies are seeking to reduce the amount of energy used. Having a compressor work overtime to compensate for leaking joints is certainly not something senior management would smile about!

These scenarios are certainly not uncommon, in fact one European compressor manufacturer has stated that in some industrial settings, up to 80% of air generated is lot in leaks. So clearly identifying these small leaks can make a real difference to a company’s energy bills.

Although the sound produced by a small leak is inaudible to the human ear a high performance acoustic imaging camera such as the FLIR Teledyne Si2 – LD will have absolutely no problem identifying the source. Launched earlier this year the camera is capable of detecting leaks of 0.05 litres per minute at a distance of 10 metres, meaning those elevated air lines pose no problem for this latest instrument in the FLIR acoustic imaging camera line up.

For closer work the camera is even more sensitive and can detects minute leaks of 0.0032 litres per minute at a distance of 2.5 metres. Coupled with this improvement, the third-generation camera has improved microphones now capable of detecting sounds over an extremely wide frequency range, namely 2 – 130 kHz.

Areas of plant are often dark or dimly lit. for this reason FLIR have fitted the FLIR Si2-series of cameras with two powerful LED lights to make component identification easy even in poorly lit conditions.

Of course, it’s not just compressed air that the camera is capable of detecting; noise emitted by any escaping gas is identified by the powerful microphones. However that’s only part of the story.

The FLIR Si2-LD has built in software termed Industrial Gas Quantification. If the leaking gas is ammonia, hydrogen, helium, or carbon dioxide, very commonly used gases in a number of industries, the software is capable of quantifying the financial loss caused by the leak. By simply entering factors such as the cost per litre, the software identifies the amount each leak is causing over a given period of time. Such data is invaluable to financial analysts and senior management within an organisation.

It goes without saying that the financial considerations are only one aspect of leaking gas. The gases mentioned above all carry significant health hazards and can present a variety of dangers to personnel if allowed to leak for any period of time. Ammonia and carbon dioxide can cause serious breathing problems and asphyxiation even in smaller concentrations, whereas hydrogen can explode in the presence of oxygen. Clearly the cost of such problems goes way beyond any financial considerations.

We’ve come a long way since the ‘soap and water’ approach. See how the latest technology from FLIR Teledyne can help in reducing downtime, lower energy bills and improve safety in your organisation.

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@flir @mepaxIntPR #TandM #PAuto

Ultrasonic imaging solutions for manufacturing, utility, and process industries.

Teledyne FLIR has announced a business and technology partnership to provide industrial customers with leading-edge predictive maintenance solutions, beginning with the FLIR Si2-Series of acoustic imaging cameras: Si2-Pro, Si2-LD, and Si2-PD.

Leveraging each organization’s deep expertise in supporting manufacturing reliability and energy conservation, UE Systems and FLIR will jointly operate throughout the world providing ultrasonic technology for condition monitoring needs over a wide range of industrial applications. The Si2-series empowers customers to pinpoint issues relating to detecting partial discharge, identifying pressurised leaks, and locating mechanical faults in industrial environments.

“By partnering together, FLIR and UE Systems can provide manufacturing-focused industrial customers with more effective acoustic imaging solutions and expertise as part of comprehensive condition monitoring, predictive maintenance, and energy conservation programs,” said Mark Bochella, Vice President of Sales and Marketing, FLIR. “The mutually beneficial combination of FLIR’s strong brand, built on its thermal imaging expertise, with UE Systems’ extensive understanding of ultrasonic maintenance programs within manufacturing environments presents an enticing growth opportunity for both organizations.”

“This partnership affords FLIR and UE Systems the ability to combine their respective strengths for the benefit of reliability maintenance programs and energy conservation across the world, starting with the Si2-Series of acoustic imaging cameras,” said Blair Fraser, Vice President, Global Technology & Business Development, UE Systems. “In the months and years ahead, we anticipate UE Systems and FLIR will explore additional opportunities for collaboration that provide comprehensive, multi-sensing solutions customers can’t find anywhere else.”

The technology and business partnership initially comprises the Si2-Series of acoustic imaging cameras, offering industrial-grade solutions that address the top inspection requirements for manufacturing, electrical, processing, and utilities organizations. The partnership also opens additional opportunities for FLIR and UE Systems to collaborate on future industrial maintenance initiatives that align with the respective priorities of each organization.

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