New process for leak detection in truck pneumatic systems during production using an ultrasound camera

Abstract: The process of producing compressed air in the industry today is highly energy inefficient. Up to 75 % of the energy spent on producing compressed air to the compressed air systems (CASs) is wasted. Out of the produced air, 24 % is wasted due to air leaks. Quality improvement is a rapidly growing demand within the motor vehicle industry because of the operating costs of waste. Compressed air is both used in industry to power tools and manufacturing, but it is also used in the complex pneumatic systems of trucks, cars, etc. The complexity is high in the pneumatic system on a heavy truck with its high number of pneumatic fittings, airlines, and valves. The risk is high for leaks in the system, originating from a smaller error in the assembly process. The study aims to introduce a new and safer method for finding leaks in the pneumatic systems of trucks that is more effective, faster, and able to locate smaller leaks compared to old methods. The research questions were answered through both quantitative and qualitative research methods. This study is based on a deductive research approach and an explanatory research purpose. Results and conclusions made from this study are that an automated pressure drop test should be implemented for purpose of quality to ensure the detection of leaks. Combined with the FLIR Si124 ultrasound camera, to find the exact position of the leak. This solution is the most reliable, standardized, and time-efficient based on the result generated by this report. The ultrasound camera could also be used for maintenance around the plant – which helps the company to reach its environmentally sustainable goals for 2025.