To ensure the top quality of their vehicles leaving the manufacturing plant, automakers are conducting water “ingress” and leak detection tests. Water ingress testing is used to help protect a variety of critical systems from dangerous contaminants. Water ingress leaks occur when water enters components through seams, holes, or porosities. Water leaks can cause fires, degrade electronics and even create surface and structural defects. Automakers are doing an incredible job of designing vehicles to go further with fewer repairs. However, the complexity of new generations of cars is putting greater pressure on engineers to ensure that components perform perfectly over the lifetime of the vehicle.

To create cars that do more, automakers must create water ingress testing systems that meet strict specifications and ensure that they adequately test the car prior to leaving the factory. Complex overbody and underbody spray systems have been created to test the limits of the vehicle. The specifications of these spray systems are tightly controlled to a pressure of +/- 2 psi. To ensure that systems are within specifications, a maintenance worker must routinely walk around and gather the critical pressure values and record them. In this vane, several challenges are created; is someone there frequently enough to capture the critical pressure values? Is it always the same person and are they getting repeatable measurements? Are there worker safety concerns in the environment or other access concerns?

Learn more about Continuous Water Pressure Monitoring in Automotive Production.