AirLeak AI

How it fits together

AirLeak AI, part by part

Scroll or tap a part. Press “See the 3D CAD design” to watch the model, built from our CAD, light each part up and show how it connects.

See the 3D CAD designShow the concept

Real-time 3D render · drag to rotate · final design may varySwipe sideways to rotate

1. 01

   The whole AirLeak AI

   A wall box reads compressor current and air pressure, works out idle leak cost and emails a weekly report. A handheld probe finds leaks.

2. 02Brain

   ESP32-S3-WROOM-1

   The brain: it runs the airleak-node firmware program

3. 03

   24-bit ADC

   Samples current and pressure at the same instant

   ESP32-S3-WROOM-1 · SPI (8 MHz) · 4 channels, about 4 kS/s

4. 

   04

   Split-core current clamp

   Reads each compressor's motor current without touching mains

   ESP32-S3-WROOM-1 · Twisted pair to ADC · 0.333 V AC signal

5. 05

   Pressure transducer

   Reads header air pressure, 0 to 200 psi

   ESP32-S3-WROOM-1 · Analog cable to ADC · 0.5 to 4.5 V signal

6. 06

   24 V wall adapter

   Powers the node from a Class 2 supply

   ESP32-S3-WROOM-1 · 9-30 V power lead · 24 V DC

7. 

   07

   Ultrasonic leak probe

   Turns 40 kHz leak hiss into audio for headphones

   ESP32-C3-MINI-1 · BLE radio to phone · Hiss level, mark-leak taps

8. 08

   All connected

   6 key parts, one program, and your phone

The idea

One small box in the compressor room puts a dollar figure on last weekend's leaks every Monday

How the parts connect

AirLeak AI, wired up

Every part, what links it to the brain, and how the data reaches your phone. A solid line is a cable; a dashed line is a radio link.

The program

What controls AirLeak AI

while (true) {
  adc.waitDataReady();                    // DRDY falling edge
  sample = adc.readFrame();               // CT1, CT2, pressure, 4-20 mA
  for (c : compressors)
    c.rms.push(sample.ct[c.id]);          // RMS per 60 Hz cycle
  if (oneSecondElapsed()) {
    for (c : compressors)
      c.state = classify(c.rms.mean());   // off / unloaded / loaded
    pressure = avg(sample.psi, 10 /*Hz*/);
  }
  if (sixtySecondsElapsed())
    mqtt.publishOrBuffer("tele", telemetry());  // flash ring if offline
}

To your phone

How the data reaches AirLeak app and web dashboard

iPhone, Android or browser

1. Node
2. Wi-Fi · MQTT over TLS
3. IEMI cloud
4. Email · web app
5. Phone or laptop

Key specs

Targets for production units; they may change during development.

Pricing

Target pricing. A 3-unit pilot bundle with a 90-day leak report is planned. Cost figures are estimates using the DOE/CAC method, not measured savings.

Indicative launch pricing in USD, excluding taxes and shipping. Final pricing is confirmed before any balance is charged.

1. 28 Oct 2026, 14:20LatestA small plant with one to three screw compressors needs to know what its air leaks cost and whether repairs held. A handheld ultrasonic detector costs $3,495 or more (UE Systems shop) and surveys happen once a year at best (sources in DESIGN.md).

   • Drawn idea plan (idea.json): the compressor room with two compressors, the dryer, the receiver and the main header running to the production floor; pins for the wall box, both current clamps, the header pressure sensor and the handheld probe
   • The product picture is now this drawn plan instead of the plain fallback card; drawn from the rev A design, not the CAD
   • Next: drawn plans for more catalogue products that still show the fallback card

   See it in 3DFull research and design

2. 27 Oct 2026, 04:30A small plant wants to know, for each compressor or big machine, whether it is running, whether the motor bearings are wearing, how much air leaks while the plant is closed, whether a panel joint is getting hot and what the dials read. Today that is five separate kits, such as a $999 Flir vibration kit, the compressor maker's own portal (Atlas Copco SMARTLINK, its machines only) and a clipboard round.

   • Combined into PlantNode (https://iemilabs.com/products/plantnode/); AirLeak itself is unchanged

   See it in 3DFull research and design