TPMS Systems for Automotive Assembly Lines

Tire Pressure Sensors

Bartec USA have a range of TPMS Test Antennas and Tools designed for different stages of the wheel and tire assembly line. These are designed to read the Tire Pressure sensors to show they are working at key stages of the assembly process and to also to test and prove that a fully tested wheel and tire assembly with TPMS is transferred to the final line.

The systems have been supplied to many wheel and tire businesses around the world including: MC Syncro, Goodyear, T&WA, Superior Wheel, Great Lakes, Topy, TWISThink, Accuride, Prime Wheel, AAP St Marys, Hayes Lemerrz, ION, Schedl, FSZM and the internal wheel and tire assembly lines of most of the OEM's.

Almost all TPMS types operate at similar frequencies enabling a common process in the plant test environment.

These systems provide the following advantages:

  • Test and record, for traceability, all information for each wheel and tire assembled and tested with TPMS (PASS or FAIL data)
  • Test for TPMS pressure upper and lower limits (preset in the system to fail if out of bounds)
  • Test for TPMS temperature upper and lower limits (preset in the system to fail if out of bounds)
  • Test TPMS battery status
  • Test TPMS accelerometer
  • Ensuring certainty that all assemblies, particularly if assembled by a third party, are quality assured before shipment to final assembly plant
  • Automated option for large volumes of TPMS wheels without impact on cycle time
  • Manual option for small volumes or run up volumes of TPMS wheels
  • Multiple sensor types can be handled by a single system
  • Leading LF and RF design ensures fast, aggressive first time read rate not affecting cycle time
  • Adjacent systems can be installed close together, without interference or cross talk saving installation space
  • Orientation of the TPMS relative to the wheel position on the conveyor can be used to ensure tire fitment does not damage the TPMS assembly.

Automatic TPM Testing Tire Line Antenna

Typical Antenna ActivationTechnology

The TPMS can be externally excited using a 125KHz Low Frequency signal and they respond with a UHF signal at either 315MHz or 433MHz.

The Bartec USA equipment ensures that the right LF datagram signals are used to activate the TPMS at the correct power level, and that the corresponding decoding is used to obtain the information from the TPMS. The reading equipment can be configured to read any TPMS and be integrated into an existing plant seamlessly.

Installation of TPMS Sensors


There are 3 main types of TPM sensor mounting arrangement to the wheel rim.

Snap fit / Pull Through Tire sensorSnap fit / Pull Through sensor

Schrader based TPM electronics with a pull through fitting which needs no special equipment to install other than a standard rubber stem puller.

Clamp in / Bolt in Tire sensorClamp in / Bolt in sensor

Most popular type of fitting adopted by most manufacturers. Usually requires a dynamic programmable torque wrench or torque profiling gun to mount. Additionally, may also require a mounting jig to assist with the installation and ensure the parts are fitted at the correct angle and a good seal is formed without breakage. Some manufacturers specify a particular torque profile and torquing process be applied to ensure a good residual torque.

Ford Banded Tire sensorFord Banded sensor

Only used by Ford and now superseded however, still original fitment on many US manufactured Ford vehicles. The TPMS sits on the rim centre and is opposite the valve stem, held in place with a steel band.

Tire Line Detection Antenna Activation AreasTesting of TPMS assembly into wheel (DETECT)


The most common method of testing TPMS fitted wheel and tire assemblies is to use an automated TPMS Test system on the assembly line after the TPMS has been fitted to the wheel. This process will test for any TPMS that is fitted over the entire area of the wheel face (as shown on the right in the image).

The typical process is:

  • Tire Pressure Sensor fitted to wheel rim
  • Tire fitted to wheel
  • Tire brought up to pressure
  • Wheel passed under the Bartec USA TPMS Test antenna and stopped for approx 6 seconds
  • LF transmitted across the face of the wheel to 'wake up' the sensor
  • TPMS transmits its data at UHF (315 or 433MHz)
  • Bartec USA equipment receives and decodes the data, which can be optionally sent to a host computer for long term storage
  • TPMS Reading Process with hand toolPass or Fail then releases the wheel to either the next process or to rework respectively

This process tests that the TPMS is still operational and (depending on where the test is performed relative to the other line operations) it is possible to check the pressure is within set limits.

All data can be stored indefinitely for future traceability of every wheel through the test system giving confidence that all assemblies are 100% functional.


Bartec USA use very technically advanced software and electronics in each antenna and controller to achieve the most reliable and aggressive reading process.

Our latest antenna, IAS (Integrated Antenna System) has multiple receivers, software downloadable TPMS types, easy setup and configuration and supports all current known TPMS types.

The Bartec USA equipment is well placed to support any future models of TPMS variant also. Every antenna is tested and mapped at our facility to ensure that a consistent LF field is presented each and every time ensuring a high quality read rate.

Tire Line Orientation Antenna Activation AreasDetection of TPMS orientation (ORIENT)


It is advisable to locate the position of a TPMS in the wheel before the tire is fitted to ensure the sensor is not damaged during the mounting process. Damage occurs if the tire bead contacts the sensor as it is being stretched over the wheel rim.

If this option is required then Bartec USA have a special ORIENT antenna.

This antenna is designed to activate the TPMS in only a specific 'pie section' of the overall wheel diameter. The testing function of the TPMS, once activated in the correct section, is the same as for the DETECT systems. All data can be logged and an audit created.

If the Tire Pressure sensor is not within the defined area then the unit test will fail alerting the plant systems so that the Tire Pressure sensor can be protected from damage at subsequent stations – usually by either repositioning (line stop) or by being taken off the line.

This can be done by a live OBD connection from the TPMS PC via a carrier to an OBD over the vehicle line or by a TPMS hand tool with OBD connectivity and programme function.


Bartec USA are able to control the field of these types of antenna such that the desired ‘pie section’ is achieved.

These are very advanced systems and rely on our understanding of the TPMS characteristics to provide a solution to very challenging requirements. As with the DETECT systems, these use the IAS antenna providing the best reading solution and the best future proofing options.

Please browse our website for more information about Bartec USA LLC and our range of TPMS Tools and our professional Tire Pressure Monitoring System support, then call toll free 855-877-9732 and speak to one of our team or e-mail us at

Proud member of these industry organizations

AAPEX AASA Automotive Aftermarket Industry Association Automotive Maintenance & Repair Association Automotive Oil Change Association Equipment & Tool Institute HDMA

IATN Motorist Assurance Program MEMA NASTF Sema Show Tire Industry Association Wheel & Tire Council

Bartec USA LLC | 44231 Phoenix Drive | Sterling Heights | Michigan | 48314 | USA

Tel: (855) 877-9732