Apogee Instruments - Weather Box
Team: Joey Walker
Project Description
Apogee Instruments currently performs ingress protection (IP) and environmental testing using inconsistent methods such as showers, dishwashers, and outdoor exposure. These methods lack repeatability and reduce testing accuracy.
This project developed a bench-scale Weather Box capable of simulating controlled rain, humidity, and temperature environments. The system enables repeatable testing for IP1–IP4 water exposure, high humidity (>95%), and temperatures up to 50°C.
The goal was to create a reliable, automated, and cost-effective testing solution to improve accuracy and reduce manual effort in product validation.
Requirements & Constraints
| Requirement | Target | Actual |
|---|---|---|
| Temperature | 50°C | 50°C |
| Humidity | 95% | ~100% |
| IP Rating | IP1 – IP4 | Achieved |
| Runtime | 7 days | 7 days |
| Temperature Stability | ±5°C | <±1°C |
Current Testing Methods
Testing Capabilities
Rain / Water
(IP1–IP4)
Temperature
Up to 50°C
Humidity
>95% RH
Long Duration
Up to 7 Days
Design Description
System Overview
The Weather Box consists of four primary subsystems working together to create a controlled environment.
Housing System
- Acrylic enclosure (Optix™ Acrylic Sheet – 1A00187A)
- Sealed with marine sealant
- Stainless steel base for strength and corrosion resistance
- Transparent walls for real-time observation
- Drain with bulkhead and ball valve
Water / Plumbing System
- Submersible pump recirculates water
- PVC (3/4 in) distribution system with angled holes
- Shower head provides low-intensity spray
- Dual system enables IP1–IP4 testing
Heating System
- Internal heating system raises temperature to 50°C
- Maintains stable temperature during testing
- Works with sealed enclosure to retain heat and humidity
Electrical & Control System
- Controls pump, heating, timer, and safety system
- Float valve maintains consistent water level
- Timer automates test duration and cycling
- Safety conditions must be met for operation
Subsystem Details
(Low Intensity)
(High Intensity)
Performance Review
Key Results
-
Achieved IP1–IP4 water exposure conditions
-
Reached temperatures up to 50°C
-
Maintained near 100% humidity
-
Operated continuously for 7 days
Testing Highlights
- No leaks observed in housing or plumbing system
- No clogging in PVC or spray system
- Stable temperature control within ±1°C
- Consistent water distribution across test area
- All systems operated as intended for 7-day continuous run
- Easy to observe and monitor through transparent enclosure
Conclusion
Design Performance
The Weather Box successfully met all major design requirements and provides a controlled, repeatable testing environment for Apogee Instruments. The system improves testing accuracy and reduces manual effort compared to previous methods.
Lessons Learned
- Importance of sealing and waterproofing in enclosed systems
- Iterative testing and troubleshooting improve reliability
- Simplicity and accessibility improve manufacturability
- Integration between subsystems is critical for performance
Future Work
- Improve automation and user interface for controls
- Add measurable flow rate control for water system
- Enhance insulation to improve thermal efficiency
- Expand testing capabilities for higher IP ratings
Building a Controlled Environment for Reliable Testing
Repeatable. Reliable. Ready for Anything.