An automated environmental test management and control application that governs multi-stage mud and water spray profiles, logging environmental conditions and cycle durations for certified IP and ingress compliance.
The Challenge
Environmental ingress and spray qualification (such as IPX rating, gravel/mud slurry impingement, and underbody splash testing) demands disciplined adherence to continuous or alternating wet-and-dry cycles. Manually switching pump valves, timing intermittent dwell periods, and logging fluid pressure and chamber temperatures often leads to cycle drift, unrecorded interruptions, and unverifiable ingress reports. When tests run unattended across hours or days, ensuring exact environmental repeatability is critical.
What We Built
We engineered a specialized desktop automation and monitoring suite tailored for environmental spray chambers and wash-down rigs. The software dictates multi-valve manifold sequencing, regulates slurry/water pump pressure, and monitors chamber parameters in real time. Built-in watchdog routines ensure that duty cycles, nozzle sweeps, and soak durations execute with second-by-second fidelity, capturing complete run telemetry and safety events in a tamper-resistant test record.
Key Capabilities
- Multi-Phase Recipe Builder: Configure complex test matrices with programmable spray durations, rest/dwell intervals, nozzle sweep oscillations, and fluid changeovers (clean water vs. mud slurry).
- Automated Actuator & Valve Sequencing: Direct PLC/IO coordination controlling pump delivery pressures, flow rates, mixing agitators, and drain solenoids.
- Environmental Condition Logging: Continuous monitoring of fluid temperature, chamber humidity, line pressure, and cycle elapsed time.
- Autonomous Error & Interruption Handling: Smart exception trapping for nozzle clogging, pressure drops, or fluid level depletion with auto-pause and cycle resumption.
- Zero-Touch Ingress Test Certificates: Automatic report compilation featuring cumulative spray duration, pressure logs, event timelines, and operator sign-off metadata.
Outcome
Converted complex, multi-day spray routines into completely hands-off, deterministic environmental sequences. Test teams eliminate timing discrepancies and flow drift, delivering verifiable ingress documentation certified for automotive, defense, and industrial equipment audits.