Leak detection with thermal imaging

Abstract

An infrared camera is used to detect leakages in a heat exchanger by an imaging process that indicates temperature differences between a heat exchanger and a pressurized gas therein. The temperature differences are created by cooling or heating either the pressurized gas or the heat exchanger, and any leakages are visually observable by the resultant image which is representative of the temperature differences. The process can be accomplished with the use of ambient air rather than the commonly used trace gases which are less desirable because of economical and environmental reasons.

Description

BACKGROUND OF THE INVENTION [0001] This invention relates generally to heat exchangers for air conditioning systems and, more particularly, to a method and apparatus for leak testing of heat exchangers to be charged with refrigerant. [0002] There are many different ways of testing the integrity of a coil or heat exchanger used in residential, commercial or industrial air conditioning and heating systems, but all of them require the use of a trace gas and a surrounding matrix against which escape of the trace gas is detectable either visibly or by the use of instruments. Such trace gases, ranging from refrigerants to inert gases, are used either to pressurize the component prior to leak detection of the outer geometry of the part or forming a surrounding environment on the component itself while the latter is subject to internal vacuum. [0003] The cost of the testing process is dictated not only on the original equipment initial costs, but on the cost of use of the trace gas in itsel...

AI Technical Summary

Benefits of technology

The invention relates to a method for testing heat exchangers by creating a temperature gradient between the heat exchanger and the surrounding vapor using an infrared camera. This allows for the detection and location of any leaks in the heat exchanger. The method eliminates the need for expensive trace gases and the need to flush the heat exchanger after testing. Additionally, a black body is placed behind the coil to prevent light reflections that may introduce errors into the imaging process. The infrared camera can also be used to improve quality control by generating input and feedback signals for peripheral equipment.

Problems solved by technology

The cost of the testing process is dictated not only on the original equipment initial costs, but on the cost of use of the trace gas in itself.

The very nature of this approach imposes a potential impact on the factory environment due to the escape of gas and non-contained leakage points.

Trace gas escapes to the factory environment are greatly undesirable not only because they represent waste in terms of cost (non recyclable nor reusable gas emissions), but also because of the increasing environmental codes and regulation in all the major HVAC regions of the world including North, Central and South America, and particularly in Asia and Europe.

This process has the disadvantage of also producing water emissions.

As of now, there are very few testing systems that are “clean” and emission free.

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