Power Safety: End-to-End Gas Monitoring Solutions for the Engine Industry

In the automotive industry, engine manufacturing and testing are regarded as the "crown jewel" of industrial production. However, behind the power output, flammable, explosive, and toxic gases are present—from emissions on engine test benches, chemical reagents in heat treatment, to volatile solvents in paint shops.

Nexisense, a trusted partner of manufacturers like BYD, Dongfeng Nissan, and Jiangling Motors, provides intelligent monitoring solutions that meet intrinsic safety and explosion-proof standards with fast response and industrial-grade precision.

Key Monitoring Points and Risk Analysis in Engine Production

1. Engine Test Room

• Risks: CO from incomplete combustion and flammable gases from minor fuel leaks.

• Nexisense Solution: Deploy SGA-500 fixed online detectors for 24/7 monitoring within the test room.

2. Special Heat Treatment and NH3 Nitrogenation

• Risks: NH3 is irritating and toxic with both toxicity and flammability risks at certain concentrations.

• Nexisense Solution: High-precision electrochemical NH3 detectors with corrosion-resistant housing.

  
  

3. Oxygen Monitoring in Confined Spaces

• Risks: Oxygen dilution may cause asphyxiation (O2<19.5% Vol).

• Nexisense Solution: Long-life O2 monitoring system with audible and visual alarms.

Nexisense Customized Product Matrix for Automotive Plants

SGA-500: Industrial Explosion-Proof Online Detector

• Intrinsic safety and explosion-proof design, die-cast aluminum housing, certified for Zone 1 and Zone 2 hazardous areas.

• Imported sensor core with high selectivity for complex engine emissions, minimizing cross-interference.

SGA-700: Smart Sensor Module

• OEM integration directly into engine test bench control panels, plug-and-play for easy maintenance and minimal downtime.

SGA-600: Portable Detector

• For inspection before maintenance in pits, fuel tanks, or enclosed test rooms, ensuring compliance with occupational safety standards.

Smart Factory Integration: From Isolated Monitoring to Coordinated Defense

• Tiered alarms: low-level triggers ventilation; high-level shuts fuel/gas valves, stops engine tests, and alerts the control center.

• Digital tracking: historical data via RS485 Modbus RTU for EHS compliance audits.

Why Leading Automakers Trust Nexisense

• Proven in practice: years of service for BYD and other new-energy and traditional power leaders with extensive field data.

• High reliability: reinforced internal components resist vibration in engine test environments.

• Rapid response: T90 sensors detect critical leaks in seconds, giving emergency response teams crucial time.

  
  

FAQ (Frequently Asked Questions)

Q1: How is stable and accurate reading ensured in high-vibration test benches?
A1: SGA-500 features reinforced circuitry, full encapsulation, and digital filtering to remove vibration noise, ensuring smooth concentration curves during high-speed engine tests.

Q2: How do sensors avoid cross-interference from both gasoline vapor and CO in exhaust?
A2: Multiple filtering layers and dual-electrode compensation technology are used. NDIR CO sensors are recommended for high-precision engine test benches due to natural immunity to hydrocarbon vapors.

Q3: Why use SGA-900 with pre-treatment for NH3 nitrogenation areas?
A3: NH3 exhaust may be hot and contain oil mist. The SGA-900 system cools and filters the sample, maintaining stable, clean gas for sensors, extending maintenance cycles from 3 to over 12 months.

Q4: What warning support is available for EV battery testing?
A4: Early thermal runaway releases H2, CO, and electrolyte vapors. Nexisense multi-parameter monitoring detects anomalies 3–5 minutes before fire, triggering ventilation and fire suppression systems.

Q5: Why do automakers prefer SGA-700 modules for integration?
A5: Plug-and-play digital sensors allow rapid on-site replacement without calibration gas, minimizing production downtime.

Q6: How to set CO alarm points in underground garages or vehicle quality check areas?
A6: Two-level alarms: 25–30ppm for STEL with fan activation; 50–100ppm triggers evacuation and enhanced ventilation. Alarm setpoints are adjustable within the system range.

Q7: Special protection requirements for gas detectors in paint shops?
A7: Dedicated shields and filters prevent paint particle blockage. Devices comply with Ex d IIC T6 Gb explosion-proof rating and anti-static coating for VOC-heavy environments.

Q8: How to integrate data into SCADA or factory control platforms?
A8: RS485 Modbus RTU allows seamless industrial Ethernet connection; WiFi, 4G wireless options for distributed EV battery testing points enable real-time, visual, traceable digital safety management.

Conclusion

Gas monitoring in the automotive engine industry is a balance of precision and speed. Nexisense’s anti-interference, vibration-resistant, and smart modular solutions provide reliable safety from traditional combustion engines to new-energy power systems. Contact Nexisense industry consultants for end-to-end custom monitoring solutions to safeguard every horsepower in your production line.