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Electronics and Semiconductors

Wireless Sensors Detect Water Leaks During Vehicle Production

03 May 2017

A complete in-line vehicle production leak detection solution developed by ON Semiconductor and RFMicron uses battery-free, wireless sensors to detect in-vehicle water leaks caused by incorrect assembly. Detecting leaks and assembly issues before a vehicle leaves the factory is critical to improving outgoing quality and to avoiding customer warranty issues. The new automated leak detection system, assembled in the production line, enables detection of the smallest damage-inducing leaks.Sensors are placed directly on the vehicle's metal chassis at the pre-trim stage and automatically inspected for leaks at the end of the assembly process. Image credit: ON SemiconductorSensors are placed directly on the vehicle's metal chassis at the pre-trim stage and automatically inspected for leaks at the end of the assembly process. Image credit: ON Semiconductor

The system employs moisture detection sensors that incorporate Magnus® IC from RFMicron. Magnus-based IC supports a revolutionary range of battery-free wireless sensors offered under Smart Passive Sensors™ and SPS™.

The RFM5126 Moisture Intrusion Detection System is able to accurately identify small leaks not detected during manual inspection procedures, with lower cost and labor impact versus traditional and less effective methods.

The unobtrusive, battery-free, wireless sensors are installed in the vehicle at the bare metal stage before installation of the interior trim and seats. After completing all assembly, vehicles move through a high-pressure spray test where the system flags any small, hard-to-find leaks. Drive-through portal stations that are easily installed on existing vehicle assembly lines facilitate communication with the sensors. The portal stations incorporate comprehensive sensor monitoring software that reports accurate leak locations helping to speed the rework process. Over time, the system strengthens process improvement efforts by helping automakers identify issues that lead to leaks in the first place.



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