ADAS - Cars of the Future

Trade tips: advanced driver assistance system repairs

Please note: a version of this article first appeared in the March/April 2019 issue of IMI Magazine and was written for a motor trade audience.

Strongly-worded manufacturer statements about fitting only original equipment (OE) parts on vehicles equipped with advanced driver assistance systems (ADAS) are common in America, and now they’ve crossed the pond.

First, Honda asserted that non-OE windscreens might cause ADAS malfunctions due to the front-facing camera not being able to aim properly. Then, last summer, General Motors (GM) warned US dealers against using aftermarket or reconditioned bumpers of all things.

To a certain extent, you can understand why they’re so protective. A recent IIHS study of GM vehicles in 23 US states found that models with auto-braking and forward-collision warning systems had 43% fewer front-to-rear crashes. It also found that 64% fewer injuries resulted from such collisions, compared to similar models without ADAS.

Closer to home, on 30 January this year, Mazda’s parts and accessories sales manager, Dave Elphick, spoke at Auto Windscreens’ Automotive Connecting Conference of only being able to guarantee ADAS if vehicles had the same parts as when they left the factory.

Alistair Carlton, technical manager at National Windscreens, agrees that the introduction of cameras and radar represents a massive change. “Until a few years ago, we in the glazing industry didn’t really deal with vehicle electrics, other than maybe a winder motor when repairing a smashed side window,” he says.

“Last year we served 30,000 ADAS customers and a third of our technicians are now ADAS-qualified. It is still a small percentage of our overall work, but it is growing fast and it won’t be long before all our technicians will need to be ADAS-qualified.

“There are two types of calibration: static and dynamic. Static requires a target board to be accurately positioned at ‘x’ point in front of the camera. The diagnostic tool asks the car if it can ‘see’ the target and, if so, make any necessary fine adjustments within the vehicle software. This needs to be carried out in workshop conditions with plenty of space, good level flooring and stable lighting.

“Dynamic calibration is more of a system check. Using a diagnostic tool, you place the car into calibration mode and go through a drive cycle, where an internal tick list is checked-off to complete the action. There are a small number of self-testing cameras which carry out the dynamic calibration themselves – maybe one day they’ll all be self-calibrating, but that’s a long way off.”

As to the VM statements, Carlton says: “We counter these claims in two ways: firstly, we only fit quality products – yes, there are inferior products out there but it would be a false economy for us to use them; secondly, we work to the standards of the VMs with the highest specifications and closest tolerances. We often find we have better kit and more expertise than the dealers. In some cases, they’re actually the customer.”

He’s spot on about needing knowledge. As Bosch points out: “The buyer of a base BMW 520SE can now opt for Driver Assistance Plus, Driver Assistance, ACC with StopGo, Night Vision, Parking Assistant or Parking Assistant Plus. Every combination of these systems will have a different sensor configuration and require a specific calibration routine.”

There’s also the small matter of finding the relevant sensor. For example, the adaptive cruise control (ACC) radar sensor on a Golf is a square device mounted below the grille. On a Passat, it’s behind the badge, where Mercedes also like to hide it. What’s more, independent garages are going to be seeing a lot more of these jobs, with JD Power’s 2018 UK Vehicle Dependability Study highlighting multiple ADAS bugs in newer premium cars.

Neil Hilton, head of business development at Hella, was on the Thatcham steering group which finalised the code of practice for glass replacement. “There would be merit in having something similar for other repairs,” he suggests. “ADAS is part of a natural progression towards fully autonomous vehicles. You see it on virtually every new vehicle now, from the largest to the smallest, the cheapest to the most expensive.

“Manufacturers are actively promoting the benefits of these systems and Ford showed the way with its sharp marketing campaign on how cameras and road sign recognition, along with speed-limiting software, can help ensure you never get a speeding ticket.

“Systems like lane departure, autonomous braking and blind-spot detection are increasingly fused together, so when you recalibrate one camera or radar you have to check the others too. Even something like changing a steering rack can affect the data line that acts as the control point for all systems across the car.

“It’s nearly six years since we launched our HGS tool and we pride ourselves on sharing information with the aftermarket. Surprisingly, there can still be a tendency among general repair workshops to think ‘this won’t affect us’, but ADAS is so widespread that our windscreen customers are now expanding into the 360-view calibration and radar.

“Block Exemption means parts must be of a reasonable standard and comparable quality. If a reset gives a satisfactory result then the system is calibrated. What’s important is to promote reputable garages – those who attend training and invest in the right equipment.”

Richard Billyeald, chief technical officer at Thatcham, has high praise for ADAS, describing it as a life-saver. “The constant influx of new systems makes it a fantastically interesting time to be involved in the industry, but we have to plan for it from a repair perspective 5-6 years down the line,” he says.

“Compare the original Tesla Model 3 to where they are now – more cameras, radar, lidar, ever more sophisticated sensors. Autonomous emergency braking (AEB) will be mandatory, but Euro NCAP is already driving it. The slope just keeps getting steeper in terms of complexity, and this means more potential for failures.

“We urge manufacturers to better support these technologies because there’s almost an information vacuum. The guidance needs to be clearer, more available and reasonable. Should you have to recalibrate after a minor scrape? The whole industry needs to align – to agree a considered approach which keeps costs under control while delivering safe repairs. We have a vibrant aftermarket in the UK and manufacturers who behave sensibly will get a reputational benefit.”

But haven’t we already had this argument – isn’t this what Right to Repair was all about? Some VMs apparently think ADAS could be key to reopening the debate.

Trade tips: electric vehicle servicing

Please note: a version of this article first appeared in the February 2019 issue of IMI Magazine and was written for a motor trade audience.

In our Dec/Jan issue, James Dillon predicted that “setting up as the local electric vehicle specialist will pay dividends in the long run”.

The experience of Tomsett MOT Centre, in Kent, gives credence to this theory. Owner Dave Tomsett explains: “I keep up with new technologies and getting into EV sounded like a wise move, so I started researching training.

“I did the one-day IMI awareness course, which was excellent, and went on to do level 1 and 2 with Bosch, and level 3 and 4 with Pro-Moto.

“We are one of very few garages to have these qualifications and, because we do trade MOTs as well as retail, we could see there was demand.

“In January 2018, we dedicated a bay to hybrid and electric, lined it out and invested in new equipment. We already had Snap-on diagnostic tools but we purchased a G-scan 2 and other kit such as insulated gloves and workshop signage.

“We did a local press launch highlighting that we were making our plug-in point available as a free resource, and it went down very well.”

Tomsett have a Prius courtesy car stickered-up to advertise that they’re an EV specialist and Dave heaps praise on the new Hybrid and Electric Vehicle Repair Alliance (HEVRA).

“We share information with other repairers and even borrow tools, which saves you buying things you might only use once in a blue moon,” he says.

Peter Melville established HEVRA following a problem with his parents’ plug-in Vauxhall. “I started in independent garages and was working for Snap-on when this issue arose with the Ampera’s air con,” he says. “The nearest franchised dealer was an hour away and several good independents wouldn’t take it.

“In the end, I found a mobile air con specialist who had the kit to work on high voltage. I realised there was a gap in the market – a service to help people find local independent garages covering EV. That was the embryo for what became HEVRA.

“We carefully vet all our members to ensure they have the appropriate qualifications and correct tools. Then, for £25 a month, we provide a technical hotline, a quarterly newsletter and advertise on all the main electric car forums, to let people know there is an alternative to the main dealers.”

Over at Pro-Moto, director Eliot Smith is at the forefront of EV training, having previously been responsible for upskilling Honda’s UK network.

“When we started Pro-Moto about 10 years ago I was on the IMI group putting together EV courses, along with representatives from City & Guilds and the Fire & Rescue Service,” he says.

“We now work with manufacturers including JLR, Hyundai, Kia, Mazda, Fiat, Toyota and McLaren, as well as independent garages, and we certified about 300 technicians to level 4 last year.

“The principles are the same on all EVs. Electricity is never going to change, the whole universe is built on it, but different manufacturers take different approaches to things like battery management.

“In the early days, we were only doing about 10 courses a year, but we’ve got five courses running concurrently next week. Demand is high.

“We unravel the complexities, give people experience of different platforms, make them aware of the risks and give them the skills to service, maintain and repair if necessary.

“Manufacturers are bringing more EVs to market but as an industry we are failing to explain it to the end user. What’s best for them – a battery car or what type of hybrid? Staff in dealerships need to be educated in these technologies to give them the confidence to explain it to customers.

“Manufacturers know where they are with the internal combustion engine. With electric, they aren’t so sure. What if there was a warranty issue? What are the options for second life batteries? How do they mitigate against these unknowns?

“What manufacturers can do is make sure their technicians have the right skills, tools and parts to service EVs, and the aftermarket must be ready to pick up where franchised dealers leave off.”

Demonstrating the depth of expertise in the repair sector, Neil Kidby, product category manager at Sealey, also did the level 2 and 3 courses with Bosch.

“We are lagging behind Europe in terms of Alternative Fuel Vehicle (AFV) penetration, but these technologies are coming and it will happen quickly,” he says. “Before long you might be powering your house from your Toyota.

“The fact is a lot of technicians are frightened of electric cars. The battery is scary, but if you take that out of the equation it is very much like working on any other car. What you must do is protect yourself and have a sealed environment.

“This isn’t as expensive or such a leap as many think. Hybrid vehicles have been around for 100 years after all. Isolate the battery and follow the manufacturers’ instructions and you will lay the foundations for the continued success of your business.

“The essentials are: an exclusion zone – barriers and signage to stop people wandering in (as a bonus this also advertises that you do this type of work); then there’s the kit – an insulation mat and gloves – and a category III voltmeter.

“There’s also the only item we sell which we hope is never used: a rescue pole. People don’t like to think about it, but you have to. In the worst case scenario, with electrocution there’s a risk that a body could catch fire if it isn’t isolated.

“In terms of sales, we’ve seen an upward trend over the last six months. We currently sell mainly to independent garages but are in negotiations with a major vehicle manufacturer too.”

Back at the coalface, Dave Tomsett concludes: “We cannot earn a living from EV alone yet, but it is growing. Overall, we’ve invested around £7.5k in new tools, training and equipment. Some jobs can be time-consuming but it’s a learning curve.

“We have a new apprentice coming in the summer and he’ll be involved with EVs from day one. That’s vital because we need to attract more skilled youngsters into the industry – working on vehicles like these should be an appealing alternative to the university route.

“Attitudes are changing; the 2040 deadline for petrol and diesel sales will focus minds, range will increase and as battery technology improves it will snowball.”

An important question we’ve not delved into is whether the government should legislate to require anyone working on EVs to have further qualifications. We’ll explore that another day.

Cars of the past: who needs seatbelts?

In the week when 97-year-old Prince Philip did his best to put road safety back on the front pages – first by smashing his Land Rover into a blue Kia, then being spotted back behind the wheel but not wearing a seatbelt – the British Safety Council reminded us of the pioneering work of controversial founder, James Tye.

Tye (pictured) campaigned tirelessly for 25 years until wearing a seatbelt become a legal requirement in 1983, producing one of the first reports on the subject back in 1959. The Department for Transport estimates the humble harness now saves around 2,000 lives in the UK every year.

Matthew Holder, head of campaigns at the British Safety Council, said: “The times when critics of the seatbelt regulations accused the government of operating a nanny state and limiting their personal freedom and comfort are long gone.”

With multiple studies showing that 90% of accidents are caused by human error, how will we look back on reasons to fear driverless cars 50 years from now?