Driving Power Safety: Full-Process Gas Monitoring in Automotive Engine Industry

In the vast landscape of the automotive industry, engine manufacturing and testing are considered "the jewel of the industrial crown." Behind the power lies a spectrum of flammable, explosive, toxic, and harmful gases—from engine test bench emissions to chemicals in heat treatment and volatile solvents in paint shops.

As a trusted partner of automakers like BYD, Dongfeng Nissan, and Jiangling Motors, Nexisense leverages industrial-grade design and precision sensing to provide an intelligent monitoring solution that complies with intrinsic safety/explosion-proof standards while offering rapid response capabilities across the entire automotive manufacturing value chain.

Core Monitoring Points and Risk Analysis in Automotive Engine Manufacturing

1. Engine Test Rooms (Test Bench)

• Risk: CO from incomplete combustion and combustible gases from fuel line leaks pose severe poisoning and explosion risks.

• Nexisense Solution: Deploy SGA-500 fixed online detectors for 24/7 dynamic monitoring inside test rooms.

2. Special Heat Treatment and Nitriding Processes

• Risk: Ammonia (NH3) is used for nitriding; it is irritating and toxic at certain concentrations, with dual toxicity and explosion risk.

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

3. Oxygen Monitoring in Confined Spaces

• Risk: Nitrogen-protected welding or storage areas may become oxygen-deficient, risking instant suffocation.

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

Nexisense Automotive Industry Product Matrix

Industrial-Grade Explosion-Proof: SGA-500 Series Online Detectors

• Dual intrinsic and explosion-proof design with die-cast aluminum housing, certified for Zone 1 and Zone 2 hazardous areas.

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

  
  

Fast and Precise: SGA-700 Intelligent Sensor Modules

• OEM integration: Plug-and-play modules fit into engine test bench control cabinets, simplifying maintenance and minimizing production downtime.

Mobile Defense: SGA-600 Portable Detectors

• Inspection: Maintenance staff use SGA-600 to perform multi-gas sampling before entering pits, tank areas, or enclosed test benches, ensuring compliance with occupational safety standards.

Smart Factory Integration: From Isolated Monitoring to Collaborative Defense

• Tiered alarm logic: Low-level alarm triggers ventilation to dilute hazards; high-level alarm shuts fuel/gas valves and stops test benches, alerting control center.

• Digital tracking: RS485 (Modbus RTU) integration stores historical data for EHS audits.

Why Leading Automakers Trust Nexisense

• Proven field experience with BYD and other major OEMs, accumulating extensive operational data.

• High reliability under high-frequency vibrations; reinforced internal components prevent solder joint failure or data drift.

• Rapid response: T90 sensor response time is industry-leading, providing critical seconds for emergency action.

  
  

FAQ: Deep Dive and Common Questions

Q1: How to ensure stable readings under severe vibration during engine test bench operation?
A1: SGA-500 series boards are fully potting or reinforced; connectors have anti-loosening clips. Sensors use imported modules with physical damping, combined with dynamic digital filtering to eliminate mechanical noise.

Q2: How to prevent cross-interference from gasoline vapors and CO?
A2: Multi-layer chemical filters and dual-electrode compensation; for strict requirements, NDIR CO sensors are recommended.

Q3: Why use SGA-900 with pre-treatment for NH3 nitriding areas?
A3: High temperature and oil mist shorten sensor life; SGA-900 cools and filters gas via semiconductor cooling + multi-stage filters, extending maintenance cycles from 3 to 12+ months.

Q4: Pre-warning support for EV battery tests?
A4: Detect H2, CO, and electrolyte vapor 3–5 minutes before fire; multi-gas fusion (H2+CO+VOCs) triggers ventilation and fire suppression.

Q5: Why prefer SGA-700 intelligent modules for integration?
A5: Digital sensors allow 10-second on-site replacement; system auto-loads calibration and range, avoiding laborious traditional recalibration.

Q6: CO alarm points in underground garages or inspection zones?
A6: Two-level alarms: 25–30ppm (STEL) triggers ventilation; 50–100ppm triggers evacuation and warning.

Q7: Special protection for paint shop detectors?
A7: Anti-paint shields and filter pads prevent clogging; Ex d IIC T6 Gb explosion-proof housing with anti-static coating ensures safety under VOC accumulation.

Q8: How to integrate data into SCADA?
A8: RS485 Modbus RTU or WiFi/4G wireless, centralized visualization, traceable digital safety management.

Summary

Gas monitoring in automotive engine industry is a balance of precision and speed. Nexisense delivers robust anti-interference, vibration-resistant structure, and intelligent modules to provide a solid safety foundation for both traditional and new energy powertrains.

Has your engine test lab or EV battery lab passed the latest EHS assessments? Contact Nexisense technical consultants for fully customized solutions from precise selection to multi-system integration, safeguarding every horsepower in the automotive industry.