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Battery-Free, wireless sensor technology detects water leaks during vehicle production

Collaboration between ON Semiconductor and RFMicron leads to effective leak detection system to improve outgoing vehicle quality, and alleviate risk of related latent malfunction and customer warranty issues

(PresseBox) (PHOENIX, Ariz., ) ON Semiconductor (Nasdaq: ON) and RFMicron have expanded their collaboration to develop a complete in-line vehicle production leak detection solution.  The RFM5126 Moisture Intrusion Detection System 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.

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™.

Vehicle assembly is a complex process involving a range of materials, glues, changing components and human-driven processes.  Even with the best traditional efforts, small leaks can go undetected during manual inspection procedures.  These leaks may allow enough water into the vehicle over time to cause mold growth and potential damage to expensive electronics modules and components. Statistics show that up to 3% of vehicles ship from the factory with leaks that will lead to mold growth and costly warranty repairs.  The RFM5126 Moisture Intrusion Detection System is able to accurately identify these leaks 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.  

“Automakers can already detect the major leaks which tend to be visible, but they have great difficulty detecting small leaks which cause damage over an extended period of time,” said Shahriar Rokhsaz, CEO, RFMicron. “The RFM5126 Moisture Intrusion Detection System identifies nearly all mold-causing small leaks and a large majority of ‘micro leaks’.  Our objective is to catch the small leaks before vehicles leave the factory.  Our battery-free wireless sensors, and our associated software, provide a highly effective and cost-efficient solution to make this happen.”

“Hard to detect leaks are a significant issue for automakers,” said Gary Straker, Vice President of the Protection and Signal Division at ON Semiconductor. “This new system automatically detects very small leaks on the assembly line, giving the opportunity to address the root causes of the problem and make process changes to improve outgoing quality.  As an added benefit, repairs at the factory are lower cost since the right materials and fully trained personnel are on-hand. Finding leaks and dealing with them earlier, combined with major reductions in repair costs, and the avoidance of any impact on an automaker’s reputation for quality, gives an attractive potential return on investment for the industry.”

For more details, please read the white paper titled Moisture Intrusion Detection System: “Solving Water Leak Inspection Challenges on Vehicle Assembly Lines”. Visit the website, watch the videos and learn more about battery-free wireless sensor technology.

About RFMicron

RFMicron’s Smart Passive Sensing™ solution has redefined, connectivity, sensing and processing data. RFMicron delivers a novel system approach to sensing, using tightly coupled hardware and software, which collects the “raw” sensor data and processes it at the central processing node. The solution eliminates the need for battery, enables passive sensing, adds intelligence to the sensor, minimizes the amount of data processing at the sensor node, and transfers the complicated data processing to be completed at a central processing location using software

RFMicron Smart Passive Sensing™ solution, brings connectivity to previously unconnected objects and situations.  Addressing diverse markets that include automotive manufacturing, health care, and industrial. RFMicron’s Smart Passive Sensing solutions are based on RFMicron’s low-cost semiconductor sensors, which operate in wireless, microcontroller-free, battery-free deployments.  The company brings the sensor data to SMART Edge devices for data reduction, analytics and cognitive processing, all designed to drive business insights.

ON Semiconductor GmbH

ON Semiconductor (Nasdaq: ON) is driving energy efficient innovations, empowering customers to reduce global energy use. The company is a leading supplier of semiconductor-based solutions, offering a comprehensive portfolio of energy efficient, power management, analog, sensors, logic, timing, connectivity, discrete, SoC and custom devices. The company's products help engineers solve their unique design challenges in automotive, communications, computing, consumer, industrial, medical, aerospace and defense applications. ON Semiconductor operates a responsive, reliable, world-class supply chain and quality program, a robust compliance and ethics program, and a network of manufacturing facilities, sales offices and design centers in key markets throughout North America, Europe and the Asia Pacific regions. For more information, visit

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