One of the areas that have been plaguing the car manufacturer are detecting and processing moisture into the vehicle. This is a major quality problem. If there is no detection and correction in the production phase, the downstream cost will be high. Moreover, although the cost of rectification may be high, it is much higher to ship the water leaking, the loss of the brand reputation is much higher, and it is difficult to correct.
The automotive industry often leads manufacturing technology because the scale and competitiveness of automobile manufacturing reflects production by automation to improve production, quality and continuity.
Now, with the next leap in manufacturing automation - the emergence of smart factories - the automotive industry has once again become one of the leaders. Intelligent Factories jointly links the industrial Internet of Things (IIOT), bringing opportunities in production plans, production projects, production implementation and testing / testing.
One of the areas that have been plaguing the car manufacturer are detecting and processing moisture into the vehicle. This is a major quality problem. If there is no detection and correction in the production phase, the downstream cost will be high. Moreover, although the cost of rectification may be high, it is much higher to ship the water leaking, the loss of the brand reputation is much higher, and it is difficult to correct.
Visual inspection method, although a little "old", depending on the attention of humanity, you can find a significant leak, but small leaks, often in the difficulty area, it is difficult or even unlikely.
By automating the process of leakage detection, it solves inconsistencies with human visual inspection and collects valuable data, and improves design and manufacturing processes.
In this article, Mesos Semiconductors will focus on making this possible perception technology and talk about how it applies to many smart plants, not just those vehicles manufactured.
Water leak test challenge
Although the electronic world is changing, there is a thing that will never change: water and electronic products are not good partners. However, in many applications, especially in devices such as electrical cabinets such as remote outdoor use, the only box or cabinet that blocks the electronic product, or for the car is the body and sealing strip.
The electronic system packaging usually performs formal testing and judging within the development cycle to ensure that it is sealed to meet the harsh use of electronic systems. However, it is also necessary to test whether to leak in the production process, especially if the button, the indicator or display is added, and it is necessary to open in the box and then sealed.
For a smaller module, a common method is an aerated test, and then the visual examination has no bubbles, and the bubbles indicate that there is a water leak. For larger items, such as electronic devices, vehicles, or, for example, rail vehicles, usually do not perform water intrusion, and water injection. This generally involves spraying with a high voltage injector controlled by robot from multiple angles to detect any and all potential leaks and accelerate the water.
In almost all cases, the product will pass through the spurting area or the water invasion, and then check if it is leaked. The most common inspection method is to let the production line operator check the product after testing. In some cases, a water contact indicator belt can be used, and when there is water, the indicator belt changes the color so that the flow is simple. In any case, this kind of inspection method is easy - the operator is always in time pressure, and it may have other irrelevant tasks while checking, and they are also easy to distract, and it is difficult to see the area that is difficult to enter. The small leakage of the product.
This test method is also very expensive. Depending on the size and complexity of the product, the operator's time is required, costly, and slow down the production process. Moreover, more expensive is that if there is a leakage, it is not seen, and the defective product reaches a business user or consumer, and then it is discovered. In this case, the cost may include returning and replacement, follow-up damage caused by leakage, and ultimately cause serious damage to the manufacturer's reputation.
"Intelligent" wireless program
An innovative, "intelligent" program RFM5126 water infringement detection system has been developed. The turnkey solution not only supports the manufacturer of intelligent factory to determine if water has been penetrated, but also provides more information on how to leak how to happen, and provide valuable data for products or process improvements.
The core of the integrated system is an Ansian Semiconductor's batteryless wireless water sensor, the brand name is a smart passive sensor (Smart Passive SensingTM or SPSTM).
These rainfall / ultra-high frequency (UHF) sensors have a back glue that is firmly attached to the product when assembled, and provides an option configuration for absorbing "tail" to support larger area. Less to 0.05 ml of water (it is popular "," a drop of water "can be read.
After spraying, the label is read by a region or manual manual reader equipped with a fixed reader. The passive sensor does not require a battery power because they use information that is collected from the probe signal to transmit information.
In the production workshop, the RF card reader can immediately indicate whether there is water leak in a particular product, and can even indicate the location of the water leakage according to which sensor is water. In the smart factory, the final product moves on the conveyor belt, and there is a leakage product will be transferred to another conveyor, bringing the product to another area of the factory to return to the main production line to eliminate water leakage.
By collecting leakage data for a while, there can be a variety of ways to provide and analyze the very valuable feedback. These data can be analyzed locally, and the data can be relaxed to other locations, such as headquarters or R & D centers, which may need to take action based on these data through IIOT, such as headquarters or R & D centers. After a while, after a period of time, there will be a problem with a particular product model or assembly process.
The system can also take in depth to individual rotary values or operators, and may find sustained people. The R & D department can also use integrated data to discover design defects, and upgrade product design and avoid problems in future products.
Summarize
The core of intelligent factory concept is to improve products and processes by using intelligent systems and data analysis, usually sharing and merging data from multiple manufacturing points through IIOT. The RFM5126 moisture intrusion detection system provides a modern and intelligent detection leakage scheme to eliminate operator errors during the detection process, and provide valuable data to analyze and improve assembly processes, and discover the defects that the product itself may exist. , Or even ongoing operator errors.
By implementing the system, there is almost no need to manually test, so that the test is more accurate, no longer discovered water leak, reduces the cost of warranty, improve customer satisfaction, and protects the brand reputation.
This is a real "smart" program, solving a long-awaited challenge, and will leak water to bring into the era of intelligent factories.
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