3% of factory-shipped vehicles incur mold and warranty repair costs due to leaks.
Development of a leak detection solution for the vehicle production process

ON Semiconductor has developed a complete in-line vehicle production leak detection solution through collaboration with RFMicron.

The moisture intrusion detection system (RFM5126) detects leaks inside a vehicle caused by improper assembly using battery-free, wireless sensors. This system utilizes a moisture detection sensor that integrates RFMicron's Magnus IC. The IC, based on Magnus technology, supports battery-free wireless sensors provided by Smart Passive Sensors and SPS.

Vehicle assembly is a complex process involving various materials, adhesives, variations in parts, and human labor. Despite the automotive industry's efforts, minor leaks can be missed during various manual inspection procedures. However, if water seeps into the vehicle due to such leaks, it can cause mold growth or potential damage to expensive electronic modules and components over time.

According to statistics, up to 3% of vehicles leaving the factory have leaks, which not only cause mold but also result in expensive warranty repair costs. The RFM5126 moisture intrusion detection system can accurately identify these leaks with less cost and labor compared to conventional leak prevention technologies.

Inconspicuous and battery-free wireless sensors are installed inside the vehicle during the bare metal stage, prior to the installation of interior trim and seats. Subsequently, while the assembled vehicle undergoes a high-pressure spray test, this system detects even small and hard-to-find leaks.

The drive-through integrated station, which is easily installed on existing vehicle assembly lines, facilitates communication with sensors. This integrated station incorporates comprehensive sensor monitoring software that reports the precise location of leaks and speeds up rework. Over time, this system strengthens process improvement efforts by helping automotive manufacturers identify issues leading to leaks at an early stage.

"Automakers can already detect major, visible leaks. However, detecting small leaks that cause problems after a certain period of time has remained a challenge to be solved," said Shahriar Rokhsaz, CEO of RFMicron. "Our goal is to catch these leaks before vehicles leave the factory using our moisture intrusion detection system (RFM5126)."