Ultrasonic system for detecting leak points in automotive fuel pumps and filters

In the automotive industry, leaks are common and often go unnoticed due to their small size. This article describes an ultrasonic system for detecting leaks in automotive fuel pumps and filters. The leaks are located by measuring the intensity of the ultrasonic signal in decibels (dB) emitted by the leaks when compressed air escapes, as the dB readings are highest at the location of the leaks. The development of an electromechanical device is described. This device pressurizes the fuel pump or filter under inspection with compressed air. These components are airtight, and the leaks generate detectable ultrasonic frequencies when the air escapes. The development of an ultrasonic detector and its probes is also described. The detector measures signals in the ultrasonic frequency range of 20 kHz to 40 kHz with intensities from 0 dB to 60 dB, and has a maximum measurement tolerance of ±2%. Furthermore, it takes two-second readings and displays a graph of the measured dB and the average dB value. The accuracy of the ultrasonic system's measurements is validated through an averaging, range, and uncertainty study, and the method for locating a leak point is demonstrated. Additionally, case studies of leak detection in gasoline pumps and filters are presented, validating the system's functionality. The ultrasonic system can be adapted for leak inspection in other hermetically sealed products by developing probes that conform to the surface geometry of the component being inspected. Keywords: ultrasound, predictive maintenance, ultrasonic detector, leak detection, air leaks, vacuum leaks, ultrasonic probe.