5 Reasons Why Your Business Needs Industrial thermal inspection lenses？

Introduction

One of the most interesting aspects of our industry is seeing how aerial survey work touches so many industries, from agriculture and forestry to environmental monitoring and search and rescue operations. 

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Our clients often have many different types of sensor assets, and one of the most specialized are thermal camera sensors. 

In this article, we'll delve into the world of thermal camera sensors for surveying, exploring what they are, the different types available, how they are used, and the advantages and potential pitfalls of using them.

What Is Thermal Imaging?

Thermal imaging, also known as infrared imaging, is a technology that allows us to capture and visualize the heat radiating from an object or scene. 

Unlike traditional cameras, which capture visible light, thermal cameras work with infrared radiation, enabling them to "see" heat variations. This feature makes them invaluable tools in diverse survey applications.

6 Reasons Thermal Camera Sensors Are Used by Aerial Surveyors

Aerial surveyors employ thermal camera sensors in a variety of ways, depending on the goals and requirements of their projects. Here are some common applications and use cases for thermal camera sensors in aerial surveying:

1. Wildlife Monitoring: Thermal imaging is an invaluable tool for tracking and studying wildlife. Aerial surveyors can use thermal cameras to locate and monitor animals, particularly in low-light or nighttime conditions.
2. Agricultural Surveys: In agriculture, thermal cameras are used to assess crop health and identify areas affected by pests, disease, or irrigation issues. This information helps farmers make timely and informed decisions.
3. Environmental Monitoring: Thermal cameras assist in monitoring environmental conditions and identifying temperature anomalies. For example, they can detect water leaks, hotspots in power lines, and heat emissions from industrial facilities.
4. Fire Detection: Aerial thermal imaging is instrumental in early fire detection. It can identify hotspots and potential wildfire outbreaks, enabling rapid response and containment efforts.
5. Building Inspections: Surveyors can use thermal cameras to inspect the thermal performance of buildings, looking for insulation issues, heat leaks, or electrical problems.
6. Power Line and Utility Inspections: Thermal cameras are employed to inspect power lines and utility infrastructure. They can identify overheating components or poor electrical connections, helping to prevent potential failures or outages.

One of our clients, Aaron Schepers, President of Cornerstone Mapping, Inc shared his experience with using thermal camera sensors:

“Thermal imaging requires an excellent working knowledge of thermal remote sensing principles. The mapping application determines the time of year for the flight and whether data collection should occur during the day or nighttime.”

Aaron shared two images from his work that illustrate some real-world application of thermal imaging. 

The image below is from a state penitentiary shows how Cornerstone Mapping used a thermal camera sensor to map underground steam lines to identify leaks. Universities and large campuses also often use steam to heat their facilities.

The next image shows how thermal imaging was used to map the location of groundwater inflows into streams and rivers in a project for the USGS. 

Cornerstone Mapping flew hundreds of miles of streams in the Nebraska Sandhills to locate groundwater inflows that are not visually identifiable. 

Groundwater maintains a yearly average temperature of around 58 degrees F, while the soil is near freezing during the winter. As you can see from the image, thermal contrast readily identifies the locations of groundwater inflows.

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What is SWIR, MWIR, and LWIR?

Cameras made especially to detect infrared wavelengths include SWIR (short-wave infrared), MWIR (Mid-Wave Infrared), or LWIR (Long-Wave Infrared) cameras. 

These terms relate to the specific portions of the electromagnetic spectrum these cameras are designed to capture. 

The differences between SWIR, MWIR, and LWIR cameras revolve around what they’re made of and how they get used.

SWIR Cameras

SWIR cameras operate in the short-wave infrared spectrum, which typically covers wavelengths between 1,000 nanometers (1 micron) and 2,500 nanometers (2.5 microns). These wavelengths are beyond what the human eye can perceive (the visible spectrum), and they extend into the infrared region. SWIR capture light reflected or absorbed by an object.

SWIR cameras are useful for aerial survey because they can penetrate through fog, smoke, and smog pollution, making SWIR cameras ideal for IR imaging through adverse conditions.

SWIR cameras are also often used in night vision and security applications due to their ability to capture infrared radiation, even in low light conditions.

MWIR Cameras

MWIR cameras are engineered to capture infrared radiation in the mid-wave portion of the spectrum, typically ranging from approximately 3 to 5 microns in wavelength. MWIR cameras detect heat emitted by an object.

Unlike SWIR cameras, they don’t work well through dust, smoke, air pollution, or fog. However, they are very good at detecting gas leaks that the naked eye can’t see, making these cameras suitable for applications like industrial inspections.

MWIR sensors are also less susceptible to atmospheric conditions. This is critical for airborne survey operations. They can operate in various climates, including those with high humidity, making them particularly well-suited to marine and coastal environments. 

LWIR Cameras

LWIR cameras are designed to capture thermal radiation in the long-wave portion of the infrared spectrum, typically covering wavelengths from about 8 to 14 microns. Like MWIR, LWIR cameras detect heat emitted by an object.

LWIR cameras are highly effective at thermal imaging in outdoor environments and building inspections due to their capability to capture the heat emitted by objects and provide temperature-related information. 

What Are the Different Types of Thermal Sensors?

Aerial surveyors have several options when it comes to thermal sensors. Each type of sensor has its own set of advantages and limitations, making it essential for professionals to choose the one that best suits their specific needs. 

Here are some common types of thermal sensors:

1. Uncooled Microbolometer: Uncooled microbolometer sensors are cost-effective and are commonly found in thermal cameras designed for consumer and lower-end applications. Because they may lack the sensitivity and accuracy of other sensor types, they are most commonly used for aerial surveys with small unmanned drones.
2. Cooled InSb (Indium Antimonide) Sensor: InSb sensors are known for their superior sensitivity and image quality. These sensors require cooling to extremely low temperatures, which can limit their use in some applications due to added complexity and maintenance requirements. Because they are so sensitive to temperature differences, these tend to be most commonly used for military and scientific applications.
3. Cooled MCT (Mercury Cadmium Telluride) Sensor: MCT sensors offer the highest level of sensitivity and resolution. They are typically found in advanced, high-end thermal cameras used for specialized aerial surveying tasks. 
4. Microgrid Infrared Focal Plane Array (IRFPA): IRFPA technology allows for the production of compact, high-resolution thermal cameras that are ideal for aerial surveying applications where size and weight constraints are critical.
5. Multispectral Sensors: Some aerial surveyors use multispectral sensors that combine thermal imaging with other spectral bands, such as visible and near-infrared. This approach provides a more comprehensive view of the surveyed area, making it useful in various applications, including agriculture and environmental monitoring.

What Types of Lenses Are Used for Aerial Surveys?

In addition to the sensor type, the choice of lens is a crucial factor in aerial surveying with thermal cameras. 

Different lenses are suited to different surveying needs, and aerial surveyors must carefully select the right lens for their specific project. Here are some common types of lenses used in aerial surveys:

1. Fixed Focus Lens: Fixed focus lenses offer a fixed field of view and focus, making them simple to use. They are ideal for applications where the surveyed area is expected to be at a consistent distance from the camera.
2. Zoom Lens: Zoom lenses provide variable focal lengths and allow aerial surveyors to change the magnification level during flight. This versatility is especially useful when the surveyed area is vast or when different details need to be inspected at varying distances.
3. Wide-Angle Lens: Wide-angle lenses capture a larger field of view, making them suitable for applications where a broader perspective is required. They are often used in environmental monitoring and disaster assessment.
4. Telephoto Lens: Telephoto lenses offer high magnification, allowing for detailed inspection of objects or terrain over long distances. They are commonly used in applications like wildlife observation or search and rescue missions.

Advantages of Using Thermal Camera Sensors

Aerial surveyors have several compelling reasons for choosing thermal camera sensors in their work:

1. Visibility in Low-Light Conditions: Thermal cameras can "see" in complete darkness, making them indispensable for nighttime and low-light applications.
2. Temperature Detection: Thermal cameras can identify variations in temperature, highlighting anomalies that may be invisible to the naked eye. This is crucial for tasks like wildlife monitoring, search and rescue, and building inspections.
3. Non-Destructive Testing: Aerial thermal imaging allows for non-destructive testing of infrastructure and equipment. It can uncover hidden issues without the need for invasive procedures.
4. Speed and Efficiency: Aerial surveys with thermal cameras can cover vast areas in a short amount of time, enhancing efficiency and reducing surveying costs.
5. Enhanced Safety: Thermal imaging helps keep surveyors safe by identifying potential hazards like electrical faults or gas leaks.

Pitfalls of Using Thermal Camera Sensors

While thermal cameras offer numerous benefits, there are also some potential pitfalls to be aware of:

• Cost: High-quality thermal cameras and sensors can be expensive, which may limit access for smaller organizations or projects with limited budgets.
• Complexity: Cooling requirements for certain sensor types, calibration, and data analysis can be complex and may necessitate specialized training.
• Environmental Factors: Weather conditions, such as rain, snow, or fog, can affect the performance of thermal cameras. Extreme temperatures may also impact their sensitivity.
• Resolution Limitations: The resolution of thermal images is generally lower than that of visible light images, which can affect the level of detail in certain applications.
• Interpretation: Interpreting thermal images requires expertise, and misinterpretations can lead to incorrect conclusions.

How Do You Use Thermal Cameras

From wildlife monitoring and search and rescue missions to agriculture, environmental monitoring, and beyond, thermal camera sensors have become indispensable tools. How do you use thermal cameras in your business?

You can see all of our cameras… RGB, NIR, Achro, and more at AERIALSURVEY.com. Let us know what questions you have. We’d love to hear from you.

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What is a thermal imager?

A thermal imager is a device which is used to detect small variances in temperature in a range of industries and settings, such as healthcare, transport and electrical maintenance. Thermal energy and infrared radiation are used to gather data on equipment and create images of them, even in low visibility situations, such as fog, haze and smoke. The device can spot a variety of electrical problems before they occur, preventing machine failure or electrical hazards. 

A lot of equipment problems in industrial environments can be identified by vibrations or sounds, but these signs don’t cover all potential issues presented by industrial equipment. A thermal imager uses a piece of kit’s thermal patterns to determine whether it is functioning normally or whether it might endure a problem. 

How does a thermal imager work?

Each piece of equipment which has a temperature of above absolute zero (-273.15 degrees celsius) emits infrared radiation. This energy that emanates from an object is called its heat signature, with a hotter temperature giving out a higher rate of radiation. The thermal imager (or camera) translates this data into an electronic image which is visible on the device interface, so the user can immediately see the temperature of a piece of equipment visually. As machines and devices are very rarely the same temperature as other pieces of equipment in their vicinity, it’s easy for the thermal camera to detect them and distinguish them from each other in its image. 

Why do data centres need thermal imagers?

The demand for data centres has skyrocketed over the last few years, with further growth expected in the next decade. Data centre facilities are being built in all four corners of the globe at a fast pace as a result of increased popularity of cloud technologies such as AI, IoT and 5G. According to a report by Research and Markets, revenues from data centres could rise by up to 60% in the next four years. 

The downtime of a data centre needs to be avoided at all costs as it has a substantial negative economic impact. But that’s not all, data centre downtime can also lead to reputational damage for a business, especially if they offer customer-facing services. As there is so much mechanical, electrical and electronic infrastructure under one roof, guaranteeing uptime has become increasingly complex for data centres. Overheating of equipment is a big concern as it can cause complete shutdown of the servers, which can affect users from all over the world. Thermal imaging cameras allow the operator to monitor the temperature of these machines to ensure that the worst doesn’t happen ahead of time.

Benefits of using a thermal imager

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Thermal imaging cameras allow you to scan wider areas for hot spots or temperature changes, unlike infrared thermometers or thermocouples. Without a thermal camera, it’s simple to overlook important factors like air leakages, areas with insufficient insulation or water intrusion. The device can scan entire buildings, HVAC (heating, ventilation and air conditioning) systems, and electronic installations. It allows you to compare the temperatures of components within the same setting much simpler, and it never misses a potential problem area. 

Save time and costs

The maintenance of data centre installations can be labour-intensive. However, due to the thermal imager’s capabilities to capture broader surface areas, they can be very effective at lowering maintenance time, speeding up inspection rounds, and detecting impending problems before they turn into costly operations. 

Carry out inspections without shutting down equipment

As thermal imaging is a non-contact method, it means that operators can execute procedures safely without having to touch any hot equipment. In addition, it also means that inspections can take place without having to interrupt the usual function of the equipment. This also saves money on scheduled downtime for machines. There are some inspections, like the rotary UPS systems, which must be carried out during operation. For these types of procedures, the thermal camera is the perfect tool. 

Take reporting to the next level

With the use of thermal imaging cameras, users may create expert, more comprehensive reports of their inspections that appeal to management and clients alike. Users can find trends by comparing recent inspections with earlier data. The usability of today’s reporting solutions is further improved by features like templates, batch processing, image editing, and route planning.

Maintenance inspections with thermal imaging

In the modern world, maintenance encompasses a lot more than just IT operations. To prevent mechanical or electrical failures and subsequent outages, power distribution centres and cooling infrastructure are also essential. A lot of systems which are vital to keep the data centre up and running heat up before they cut out. Infrared thermography (thermal imaging) is a perfect instrument to evaluate power consumption, electrical installations, cooling equipment, and computing gear because temperature is a significant indicator of energy consumption and equipment operation.

Predictive and preventative maintenance strategies have become completely dependent on routine inspections with a thermal imaging camera. Maintenance personnel can identify issues with electrical switchgear, motors, HVAC infrastructure, uninterruptible power supplies (UPS), power distribution units (PDU), batteries and generator equipment and all electrical devices that supply the server systems, using thermal cameras. Thermal imaging makes it possible for maintenance staff to identify any issues before they result in major failures and significant downtime. 

Higher computer density and power efficiency are becoming increasingly necessary as cloud computing becomes the new norm and data centres grow exponentially. Owners of data centres are looking for ways to expand their capacity while also lowering costs and energy use.They can use thermal imaging to get crucial data on how to reduce their energy and space needs while preventing overheating.

Routine thermal imaging checks can assist maintenance personnel to: 

• Identify any hidden issues and address them before they result in unscheduled overtime. 
• Reduce the possibility that circuit overloads or weak connections will cause component degradation to go undetected.
• Prevent equipment failures. 
• Achieve optimal space and energy management. 

Where can thermal imaging be most effective?

In order to handle the many maintenance and inspection tasks for data centres, thermal imaging is the ideal technology.

In order to handle the many maintenance and inspection tasks for data centres, thermal imaging is the ideal technology.

Electrical and mechanical systems

A range of electrical or power-generation related systems can be inspected using thermal imaging cameras. When monitoring the condition of an electrical installation, heat is a very good indicator of any defects it might have. Heat is produced when current flows through a resistive element. Electrical connections may become more resistant with time, as a result of corrosion and loosening. The corresponding rise in temperature can cause components to fail, leading to unplanned outages. 

Load imbalances and increases in current impedance are some issues that electrical systems may encounter. Thermal imaging can quickly locate hot spots, determine the severity of the problem, and help establish the time frame in which the equipment should be repaired.

Thermal imaging cameras can help to detect issues with: 

• Overheated connections
• Overloaded or imbalanced circuits
• Damaged switches
• Faulty fuses
• Power supplies
• Battery systems
• Generator systems
• Uninterruptible Power Supplies (UPS)
• Transformers
• Electrical panels
• Resistive load banks

HVAC and cooling systems

Data centres require ideal air-cooling conditions in order to operate smoothly and effectively. A hot aisle/cold aisle configuration is frequently used in data centres. Server racks are arranged in aisles with the fronts facing each other. The cold aisles receive cold air from the Computer Room Air-Conditioning (CRAC) unit, which is located at the bottom of the raised floor. This cool air chills the servers on the racks. At the same time, the rears of the servers pump out hot air to the hot aisle, which is then directed back to the CRAC unit. 

A range of electrical or power-generation related systems can be inspected using thermal imaging cameras. When monitoring the condition of an electrical installation, heat is a very good indicator of any defects it might have. Heat is produced when current flows through a resistive element. Electrical connections may become more resistant with time, as a result of corrosion and loosening. The corresponding rise in temperature can cause components to fail, leading to unplanned outages. 

Load imbalances and increases in current impedance are some issues that electrical systems may encounter. Thermal imaging can quickly locate hot spots, determine the severity of the problem, and help establish the time frame in which the equipment should be repaired.

Thermal imaging cameras can help to detect issues with: 

• Overheated connections
• Overloaded or imbalanced circuits
• Damaged switches
• Faulty fuses
• Power supplies
• Battery systems
• Generator systems
• Uninterruptible Power Supplies (UPS)
• Transformers
• Electrical panels
• Resistive load banks

HVAC and cooling systems

Data centres require ideal air-cooling conditions in order to operate smoothly and effectively. A hot aisle/cold aisle configuration is frequently used in data centres. Server racks are arranged in aisles with the fronts facing each other. The cold aisles receive cold air from the Computer Room Air-Conditioning (CRAC) unit, which is located at the bottom of the raised floor. This cool air chills the servers on the racks. At the same time, the rears of the servers pump out hot air to the hot aisle, which is then directed back to the CRAC unit. 

As data centres are packing more servers into their racks nowadays, thermal imaging has grown in importance as a way to ensure optimal hot aisle/cold aisle performance. Users will be able to identify issues like misaligned ducting and electrical failures using thermal cameras, and then decide what corrective actions to take. Using a thermal imaging camera during an HVAC inspection can:

• Monitor server rack temperature distribution patterns
• Locate misrouted and leaking ducts
• See electrical or mechanical CRAC unit defects
• Confirm the source of energy losses
• Find missing insulation
• Discover AC condensate leaks
• Find internal server fans which are inoperable or damaged

As data centres are packing more servers into their racks nowadays, thermal imaging has grown in importance as a way to ensure optimal hot aisle/cold aisle performance. Users will be able to identify issues like misaligned ducting and electrical failures using thermal cameras, and then decide what corrective actions to take. Using a thermal imaging camera during an HVAC inspection can:

• Monitor server rack temperature distribution patterns
• Locate misrouted and leaking ducts
• See electrical or mechanical CRAC unit defects
• Confirm the source of energy losses
• Find missing insulation
• Discover AC condensate leaks
• Find internal server fans which are inoperable or damaged

Solar power

The solar panel, which is the most crucial component of a solar system, needs to be dependable and able to continue producing electricity for many years. Unfortunately, solar panels can get damaged. Therefore, to swiftly identify solar panel issues down to the cell level, maintenance specialists scan solar panels deployed on rooftops or in solar parks using thermal imagers.

The solar panel, which is the most crucial component of a solar panel system, needs to be dependable and able to continue producing electricity for many years. Unfortunately, solar panels can get damaged. Therefore, to swiftly identify solar panel issues down to the cell level, maintenance specialists scan solar panels deployed on rooftops or in solar parks using thermal imagers.

Renewable energy

The usage of renewable energy sources, such as solar and wind energy, is improving among data centre operators. Data centres may lessen their environmental impact while still achieving long-term sustainability objectives thanks to these renewable energy sources.

Physical security

Thermal cameras can identify more than just temperature variations or hotspots. They aid in defending a physical border against unwanted intruders or trespassers. As data centres operate 24/7, they require efficient technologies that will enable continuous monitoring of the facility. 

For data centre deployments, thermal security cameras with high contrast, high resolution, and long detection ranges are perfect. Thermal cameras can observe in most adverse weather conditions, such as light rain, fog, smoke, or complete darkness, unlike standard video cameras.

Thermal cameras are able to distinguish between a person and a vehicle when used in conjunction with video analytics. When thermal imagers are combined with radar, the customer is no longer needed, which helps to eliminate human error. Remote operators can evaluate thermal and visible video feeds of the area for better alarm verification and intruder identification by integrating thermal cameras with HD visible cameras.

What specs should be considered when deciding which thermal imager to buy?

Range – this refers to the span of temperatures the camera is able to measure. Choosing a higher temperature range is vital for measuring hotter industrial applications such as boilers, kilns or furnaces. When a camera is out of range and unable to measure an object’s temperature, an asterisk appears next to the number to indicate that the camera is estimating the temperature. 

Field of view (FOV) – FOV is dependent on the lens and relates to how much you can see through the lens. For up-close work a FOV of 45° or higher and for longer distance jobs a telephoto lens is needed (6°or 12°). 

IR resolution – this refers to the amount of pixels on the screen. The higher the resolution, the more data the camera can collect. 

Thermal sensitivity – sometimes called Noise Equivalent Temperature Difference (NETD), thermal sensitivity concerns the smallest difference in temperature the camera can pick up. The lower the number, the more sensitive the thermal camera is. 

Focus – thermal cameras usually have three types of focus: fixed, manual or automatic. Fixed means it’s always in focus, manual means the user must modify it themselves, and automatic means the camera will focus automatically based on what it can see. 

Spectral range – this refers to the range of wavelengths that the thermal camera can detect.

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