Thermal Imaging
Thermal imaging (infrared thermography) is a non-contact, non-destructive testing (NDT) condition monitoring technique that detects infrared radiation emitted by objects above absolute zero, converts it into a visible thermal image, and maps temperature disparities using color gradients to reveal abnormal heat or cold spots indicating developing equipment faults.
On the shop floor, technicians perform periodic handheld scans or deploy fixed remote sensors on high-load assets such as electrical panels, motor bearings, and process equipment while operating at ≥40% load to generate detectable thermal signatures. Baseline thermal profiles of healthy equipment are established and compared against current readings; deviations exceeding set thresholds automatically trigger CMMS work orders for corrective action. Results, including numeric temperatures and annotated images, are integrated into CMMS asset records for long-term trending, severity categorization, and correlation with vibration, oil, and ultrasound data.
What is the detection rate for thermal imaging in electrical vs. mechanical systems?
Identifies 85–90% of electrical faults (overheating connections, insulation degradation) and 70–80% of mechanical issues (bearing friction, blocked cooling paths) weeks before catastrophic failure.
How does AI-enhanced thermal imaging differ from handheld surveys?
AI systems apply computer vision to continuous infrared video frames, auto-classify fault severity against learned baselines, and generate work orders without requiring certified thermographers per image.
What environmental factors most affect thermal accuracy?
Ambient temperature, reflected radiation from nearby hot surfaces, and airflow (convection) can distort readings; operators must compensate via emissivity settings and reflected-temperature calibration.