Automotive Solutions

As vehicle technology continues to advance, automotive manufacturing is becoming increasingly automated, connected, and quality-driven. From electric vehicle battery production to sophisticated electronic systems and precision-molded components, manufacturers face growing demands for consistent quality, contamination control, and process reliability.

Electrostatic charge can impact product quality at nearly every stage of automotive manufacturing. Uncontrolled static can attract contaminants, interfere with automated processes, damage sensitive electronic components, and contribute to production defects. Effective static control helps improve product quality, increase production efficiency, reduce waste, and support reliable, traceable manufacturing processes.

Automotive Manufacturing Applications

EV Battery Manufacturing
- Control static during battery cell, module, and pack assembly to minimize contamination, protect sensitive components, and improve production reliability for electric vehicle batteries.
Plastic Parts Molding
- Neutralize static on molded plastic components such as dashboards, instrument panels, center consoles, door panels, bumper covers, grilles, and trim pieces to reduce dust attraction and improve downstream processing.
Precision Milling & Machining
- Reduce static on machined metal and composite components, including housings, brackets, structural parts, and powertrain components, helping prevent debris buildup and improve part cleanliness before assembly.
Painting & Coating Preparation
- Remove dust and contaminants from body panels, bumper fascias, mirror housings, spoilers, and other painted components prior to coating, resulting in improved finish quality and fewer paint defects.
Interior Trim Assembly
- Eliminate static on interior components such as dashboard assemblies, door panels, center consoles, headliners, pillars, and decorative trim to reduce contamination and simplify automated handling and assembly.
Electronic Assembly
- Protect electrostatic-sensitive components including infotainment displays, digital instrument clusters, touch panels, printed circuit boards (PCBs), sensors, camera modules, and electronic control units (ECUs) from electrostatic discharge (ESD) during manufacturing and assembly.

Whether protecting sensitive electronics, improving paint quality, or reducing contamination throughout production, Simco-Ion helps automotive manufacturers optimize processes while meeting today's demanding quality standards and preparing for the manufacturing challenges of tomorrow.

IQ Easy Modular Sensor

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The newest member of the IQ family is also the smallest and most capable. The Modular Sensor is an advanced non-contact electrostatic field meter designed to accurately measure and communicate static charge levels (up to 60 kV) while eliminating the time requirement and inaccuracy associated with handheld measurements. The Control Station offers high speed digital communication, user-configurable alarms, and optional PLC integration so that areas where static charge is a problem can be constantly monitored, and ionizer performance documented and improved via Closed-loop Feedback (CLFB).

The IQ Easy Modular Sensor is an electrostatic field measuring sensor. There are two versions of this modular sensor; one contains a single M12 input, while the other contains two RJ-45-style connectors (one on each end of the sensor). The dual-input RJ-45 sensor is designed to work in a daisy-chained (pass-through) fashion, while the M12 sensor is designed to work as a standalone device. The IQ Easy Modular Sensor is a single sensor bar best suited for use in plastic film and web processing applications. It can monitor processed materials for the presence, polarity, and degree of electrostatic charges. This allows for the detection of undesirable levels of static electricity.

Static charge may not be readily apparent on processed materials but often makes itself noticeable in static shocks to machine operators, mis-fed materials, jammed operation, and the attraction of dust and dirt. The Modular IQ Easy Sensor makes the intangible tangible by providing hard data about electrostatic charges on processed materials. This data can easily be correlated to machine operation or mis-operation. Being aware of static charges can even make process troubleshooting easier, for example, understanding coating irregularities as they relate to the level of static charge.

Features & Benefits

Connect up to 40 modular sensors to one control station
Certificate of Calibration available
Air purge connections for demanding environments
Five communication protocols for PLC connection
Configurable for static charging, neutralizing, or CLFB applications

Power Supply	IQ Power Control Station
Input Voltage	24 VDC, 0.075 mA
Input Connection	5-pin M12(A-coded) female receptacle; RJ-45 female receptacle
Input Purge Gas	1-2.5 psi(7-17 kPa) operating pressure 5 psi(35 kPa) max operating pressure 0.14 scfm(4 NL/min) @ 1 psi(5 kPa) 0.22 scfm(6 NL/min) @ 2.5 psi(20 kPa) Clean, dry, filtered, oil-free compressed air or nitrogen
Gas Input Connection	4 mm OD Tubing, Quick Disconnect
Operating Environment	122°F(50°C) max; 70% RH, no dewing permissible(max)
Operating Distance	2"(50mm), 20 kV max 3"(75mm), 25 kV max 4"(100mm), 30 kV max(factory default setting) 6"(150mm), 40 kV max 8"(200mm), 50 kV max 10"(250mm), 60 kV max
Enclosure	Glass fiber reinforced plastic
Dimensions	RJ-45: 8.02"L x 1.19"W x 2.08"H (including mounting bracket & connector) M12: 8.09"L x 1.19"W x 2.08"H (including mounting bracket & connector
Weight	0.9 lb/ft (1.3 kg/m)
Compliance	RoHS
Approval	ETL, US, Canada