Numerous industries have seen a revolution thanks to acoustic imaging technology. It provides a new approach to sound analysis by accurately visualizing sound sources. This improves dependability, assures safety, and substantially contributes to industrial maintenance. In this post, we will look at the principles of acoustic imaging in mining operations and its advantages.

The dangers of undetected air leaks in mining operations

The industrial machinery, tools, and other procedures found on mining sites can be overwhelming. They require a great deal of energy, people, timing, and precision to achieve the desired outcomes. 

Compressed air is a crucial part of the whole operation. Air compressors facilitate a variety of purposes, including powering machinery, supplying clean air, and providing ventilation to make processes safer and more effective. 

In addition to making mining safer and more effective, compressed air systems are the industry’s preferred method since they are convenient and flexible. They do well in various mining operations and are resilient to severe wear and tear. 

Today, between 10% and 20% of a mine’s electricity comes from compressed air generation. However, over time, leaks in compressed air systems can raise energy costs by making the compressor work harder. Joints, weak spots, and pressure level changes are common places where leaks develop. These issues can decrease the effectiveness of air-operated tools and lengthen the time needed to do tasks. 

Additionally, leaks degrade the equipment’s service life and raise maintenance expenses. They increase the compressor’s operating time and cause needless cycles. Associated expenses can quickly increase: detecting compressed air leakage can save 2.3% to 5% of the mine’s overall energy costs.

Acoustic imaging technology to the rescue

Acoustic imaging has the potential to revolutionize leak detection. Among its many advantages are its versatility, speed, accuracy, safety, non-invasiveness, and ability to maintain operations. 

A mining extraction camera uses an acoustic array of tiny, extremely sensitive microphones that can pick up both sonic and ultrasonic sound waves. After identifying a sound source at a possible leak location, the acoustic imager uses proprietary algorithms to interpret the sound as a leak. The outcome is a color map that is placed on the visible light image, indicating the precise location of the leak. 

When paired with cloud service connectivity, the integrated system immediately saves photos to the cloud as soon as they are taken. An operator and team can then access saved files, separating sound sources for more in-depth problem classification and analysis.

A summary of the steps in acoustic imaging technology

The ability of a mining camera to precisely transform sound waves into visual information is exceptional. There are numerous crucial steps in the process:

• Sound wave capture: Sensitive microphones or sensors are positioned in strategic locations to pick up sound waves coming from various directions and record changes in timing and strength.
• Data collection: These sensors provide the information to a central processing unit after recording sound characteristics, including frequency, intensity, and detection time.
• Data processing: Sophisticated algorithms examine the data and compare sound intensities and time delays to pinpoint the exact source location.
• Visual Representation: Processed data is shown graphically, frequently as a “sound map” or “sound image.” It uses color coding or shades to show the sources and intensities of sound.
• User interface: Users can precisely identify and analyze sound sources by interacting with the visual depiction.

Even in highly complicated and noisy locations, acoustic mining cameras have the benefit of quickly and accurately locating the source of a leak with little operator training. The operator just needs to aim the camera at potentially leaking pipes, equipment, and lines and point and shoot. As a result, mining facilities are able to act quickly to reduce energy waste, reduce safety hazards, and improve equipment performance. 

Key advantages of acoustic imaging technology for mining operations

A higher level of energy efficiency

Compressed air leaks are a major source of energy waste in the mining sector. However, miners employ acoustic imaging cameras to promptly identify and repair leaks. This can increase their energy efficiency and lower overall energy usage. Consequently, it lowers operational expenses and the impact on the environment.

Identifying anomalies early

Acoustic imaging makes it possible to identify problems like leaks or mechanical wear early on. This ability is essential for avoiding production disruptions, reducing safety risks, and averting expensive malfunctions.

Non-destructive examination

The fact that acoustic imaging doesn’t involve physical touch with equipment is a significant benefit. This non-intrusive approach decreases downtime during inspections and lowers the possibility of machinery damage.

Productivity gains

Compressed air leaks hinder the effectiveness of pneumatic equipment. They can have a detrimental impact on mining operations’ production. Mining businesses can increase overall production and maximize equipment efficiency by promptly detecting and fixing these leaks using acoustic cameras.

Uses a larger frequency range to identify malfunctions

Acoustic imagers provide detection in frequency bands from two to 100 kHz. On the contrary, airborne ultrasonic sensors only allow detection in a single frequency at a time (e.g., the 30-kHz range). Mining extraction cameras can also restrict the frequency bands they use if they so choose. Additional frequency bands offer the imager a greater range to detect abnormalities. This includes ones that might not be evident at 30 kHz and provide more data.

Enhanced safety 

Acoustic imaging can be conducted safely away from moving mining equipment, inaccessible areas, and other hazardous situations. Up to 50 meters can be used for inspections, which makes the workplace safer.

No skilled training is required

Acoustic imaging detection does not require specialized knowledge or training. Compared to other inspection techniques, it is easier and faster to use. It has a user-friendly design and sound visualization. This saves time for both conducting the inspection and analyzing the findings.

Data visualization

Acoustic imaging can visually present anomalies and sound sources. This visual data allows maintenance crews, operators, and management to make better decisions and communicate more effectively.

Conclusion 

Compressed air leaks can hinder the effectiveness of pneumatic equipment and negatively impact mining operations. This is where an acoustic imaging camera can really help. Mining businesses can improve overall production and equipment performance by quickly detecting and fixing such leaks.