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System Overview

System Architecture

Reveal consists of five major subsystems.

1. Ultrasound sensing front-end

The acoustic front-end is responsible for capturing ultrasonic leak emissions, amplification of the received signals, analog filtering and signal conditioning.

2. Optical camera subsystem

The optical camera subsystem provides a live video stream to be used by the processing unit for creating an overlay.

3. Processing unit

The processing unit handles the data acquisition of both the video stream and the ultrasound sensing front-end. This is followed by a spectral analysis of the incoming ultrasound stream, a source localization algorithm to pinpoint the leaks, and finally sensor fusion to overlay the acoustic soundscapes on to the real-time images. Handles:

4. Visualization layer

The visualization layer generates leak localization markers, heatmap overlays and confidence indicators to the operator to accurately assess potential pressurized air leaks.

5. User interface

The user interface allows operators to view live diagnostics, capture inspection results and export reports.

Device

Device

Device

Hardware Development

Ultrasound frontend design

Development included sensor selection, low-noise analog amplification, anti-aliasing filter design and PCB layout optimization.

The key considerations in this process can be summarized as: - High-frequency sensitivity - Noise floor minimization - EMC robustness

PCB integration

The Custom PCB development addressed analog-digital isolation with focus on power integrity and a cautious implementation of high-speed acquisition paths.

Firmware and Software Development

Embedded firmware

The developed embedded firmware is responsible for sensor sampling, timing synchronization between the two modalities and data transport.

Signal processing software

The core algorithms on the Reveal include:

  • FFT-based spectral analysis
  • Leak signature extraction
  • Source localization

Optical fusion software

Performs:

  • Camera calibration
  • Coordinate mapping
  • Overlay generation

Enclosure Development

The enclosure was designed to support industrial deployment.

Design considerations:

  • Ergonomics for handheld use
  • Sensor aperture placement
  • Thermal management
  • Mechanical robustness

Manufacturing methods:

  • CNC machining
  • 3D printed prototyping
  • Injection molding readiness

Finished Product

Reveal demonstrates a fully integrated industrial diagnostic platform capable of detecting compressed air leaks, localizing leak sources, providing intuitive operator visualization and most importantly supporting preventive maintenance workflows.