Onsemi and RFMicron have teamed up to develop a complete solution for detecting water leaks in vehicle production lines

     ON Semiconductor and RFMicron have expanded their collaboration to develop a complete water leakage detection solution for vehicle production lines. The RFM5126 water intrusion detection system uses a battery-free wireless sensor to detect water leaks inside the vehicle caused by assembly errors. Detecting water leaks and assembly problems before the vehicle leaves the factory is critical to improving the quality of the vehicle leaving the factory and avoiding customer warranty issues. The new automatic leak detection system, installed on the production line, will detect the smallest leaks that can cause damage.

     The system uses moisture detection sensors, including RFMicron's Magnus IC. Magnus based ics support a range of innovative battery-free wireless sensors from On Semiconductor, named Smart Passive SensorTM and SPSTM.

     The process of automotive assembly is complex, involving a range of materials, adhesives, replacement components and manual processes. Even with the best efforts of traditional methods, there may be small leakage problems that go undetected during manual inspection procedures. Over time, the water that leaks into the car from the leak is enough to cause mold growth and potential damage to expensive electronic modules and components. Statistics show that up to 3% of vehicles manufactured have water leakage problems, which can lead to mold growth and expensive warranties. Compared to traditional and less efficient methods, the RFM5126 water intrusion detection system can accurately detect these leaks at a lower cost and with less labor.

     Unobtrusive battery-free wireless sensors are installed in the car during the bare-metal stage before the installation of the car's interior and seats. After all assembly is completed, the vehicle is subjected to a high-pressure spray test, where the system flags any small, hard-to-detect water leaks. The car is driven through portal stations that are easy to install in existing automotive assembly lines, facilitating portal stations to communicate with sensors. The portal stations feature comprehensive sensor monitoring software that reports the exact location of water leaks, helping to speed up the rework process. Over time, the system helps automakers identify problems that cause water leaks in the first place, enabling enhanced process improvement efforts.

     Shahriar Rokhsaz, CEO of RFMicron, said: "Car manufacturers can already detect where major leaks are obvious, but they struggle to detect small leaks that cause damage over a long period of time. The RFM5126 water intrusion detection system detected almost all small leaks caused by mold and most 'microleaks'. Our goal is to detect small water leaks before the vehicle leaves the factory. Our battery-free wireless sensors and associated software provide an efficient and cost-effective solution to achieve this goal."

     "The difficulty of detecting water leaks is a significant problem for automakers," said Gary Straker, vice president of protection and signals at ON Semiconductor. The new system automatically detects small leaks on the assembly line, addressing the root cause of the problem and changing the process to improve the quality of the vehicle leaving the factory. The added benefit is that plant maintenance costs are lower because the right materials and trained personnel are on site. "Early detection and treatment of leaks significantly reduces repair costs and avoids any impact on an automaker's reputation for quality, providing the industry with an attractive potential return on investment."