Technology & Repair Techniques Explored
By Mitch Becker
ADAS systems depend on clear vision and proper calibration because the hi-def cameras used in vehicles today play a key role in keeping drivers safe.
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Most of us use the camera feature in our phones at some point. To the user, it’s a simple device: Just point and shoot. Many of us also remember when phones with cameras first came out. Looking at the photos those cameras took, we realize that, compared to today, the quality of the cameras has improved.
The quality of cameras used in vehicles today, featuring high definition and the ability to see more vibrant colors, is a key factor in how they work in vehicles equipped with advanced driver-assistance systems (ADAS). This improved quality of picture is critical for occupant safety in that how clear the vehicle sees affects the safety systems’ performance.
Like your own phone, where the camera is aimed also makes a big difference in the context of what the camera sees. Regular people can pursue training and classes on how to take better pictures using lighting and subject placement. But even in the collision industry, there are guidelines on how to take better photos of vehicle damage so anyone viewing those photos can see the damage. Now take this thought process and look at all the cameras on today’s vehicles, and you begin to understand cameras being used as part of a car’s ADAS safety systems.
The Whole System
The camera is only part of the system; software being used in the computer uses the captured images produced by the camera for safety system functioning. The clarity of the camera images provides computer algorithms the information needed to identify and react to perceived danger. These reactions could be warnings in passive systems to steering and applying brakes in active systems. Without the clarity of the image, the algorithm may not see perceived danger and provide necessary information to the driver, not react as designed or even give false alarms to the driver, making the driver confused or not trust the system.
To give more context to the environment of each moment depending on year, make and model of vehicle, the sensor fusion between cameras and radars and lidar give the vehicle algorithm information on distance, vehicle speed, road conditions and operation of vehicle systems, such as brakes, steering wheel position, GPS and even vehicle-to-vehicle communication. The information the sensors provide must be clear because, as is the case with all computers, the phrase “garbage in, garbage out” applies.
It’s no different than your eyes while driving. For those who wear glasses or contacts, or even those lucky to have good eyesight but are wearing dirty sunglasses, that visual impairment makes a big difference in how your brain reacts to its surroundings. With all of your own personal experience from driving a car, you see and compare all these same parameters, and the algorithm sees and reacts accordingly in your driving. The problem with us humans, though, is that we get distracted. The vehicle, on the other hand, is ever-vigilant.
Far from Perfect
Cameras are not perfect sensors; no one sensor is. Just like human eyes, they have limitations that affect what they see. We’ve all encountered construction when driving and wondered: Where am I supposed to go? Even though ADAS systems are amazing, in compromised situations, the driver must be aware of all of his or her surroundings. When this occurs, a “system disabled” warning may be displayed to the driver. In most situations, the system remains stable and operates correctly as long as all sensors are aimed and working correctly. Some vehicle manufacturers use multiple cameras in the windshield, which provides a much better platform for the vehicle’s algorithm to see road hazards and react more efficiently or effectively. This is why calibrations are necessary whenever a system or sensor such as a camera is moved. That movement can change the focal point of that camera and reduce the ability to see in full context what is needed for the vehicle to react. Where and how cameras, or any sensor for that matter, are aimed changes the reaction time of the vehicle as well as braking or steering. That’s everyday use of the system and operating parameters.
When calibrating camera systems, the environment for the calibration of a camera must meet specific conditions. This is a relearning process. During the calibration, very specific images are used in the algorithm and must be met to a specific percentage of clarity or perfection and in proper location in reference to the vehicle in that algorithm to be sure the camera is seeing correctly … or the calibration fails.
All of us at some point have dropped our phones and picked them up. We then check for a cracked screen, and if it’s damaged, we know we have some repairs to do. Vehicle cameras aren’t designed for severe shock damage, because they don’t get dropped. Besides, while properly attached to the vehicle, the vehicle protects against most road shock due to the suspension, tires and other features providing a smooth ride. Therefore, collision technicians who handle these cameras need to be aware of how much care should be involved.
In regard to forward-facing cameras in windshields, there could be other sensors included in those cameras that may be negatively affected by mishandling. In some cases, while the vehicle engine may be off, the camera may still be active, which may be a concern during a calibration process that takes too long and causes the camera to overheat. Rollover sensors may also be a concern in new vehicles.
Here are some best practices when handling forward-facing cameras that will help you avoid damaging them — and also avoid costly replacement:
- Always conduct a pre-repair scan on a vehicle prior to doing any work. Cameras have been known to fail or have DTCs preventing calibrations from being completed.
- Never let the camera hang from wires.
- When removing a camera from a windshield, wear powder-free nitrile gloves and do not touch the lens. Lenses may have an anti-fog coating and will be damaged if touched or oil from skin gets on them. Unless a specific service information procedure is available, do not clean the lens, as you will damage the coatings.
- Store in a Ziploc bag to prevent dirt and other materials from damaging the lens.
- Store in a protected area to prevent from getting moved, dropped or damaged.
- Always keep the camera upright unless otherwise noted by service information.
- Be careful of heaters attached to cameras, as they break easily and may require initialization and programming if replaced.
- Replace pads when required for replace and install (R&I). Pads may be silicon-like gel pads designed to keep cameras stable and also keep any moisture or debris from the viewing area.
- Install the camera verifying that all circuit board pad sensors are touching the glass where required.
- Be sure the camera is mounted correctly and tight when attaching back to the bracket.
- All connectors must be correctly fastened, and double-check before a calibration is attempted.
- Vehicle alignment must be in accordance with OEM specifications, as this may have as much of an effect on camera aiming as the camera placement on the windshield.
These are only a few considerations; you may have more. That all comes with experience and is different between year, make and model of vehicle. Even the type of lighting systems in a shop can create an issue with some cameras.
When you experience a failed calibration, grab a camera and take a picture of what the vehicle camera sees. Look for background clutter, light glare, dirt, whatever would make it a bad picture. Correct those issues and try again. A large majority of calibration failures are due to technician error regarding the environment during calibration.
Vehicle cameras see and track images for the vehicle’s computers. The system recognizes signs, cars, people, bikes, trees, bushes, etc., and it sees, identifies and classifies these images every millisecond and adjusts or disregards.
Most of what I’ve been referring to is the forward-facing camera on the vehicle’s windshield, but surround-view and rearview cameras also have considerations. Although the handling may not be as critical, as most of these cameras are located outside of the occupant compartment and are subject to much more shock from everyday use, there are still service information guidelines relating to mounting and calibrations. This is where the lighting system in the shop may affect calibrations. As with all sensors, mounting them correctly is a critical step to be sure they’re aimed correctly.
Summary
We can relate to cameras through the everyday use of our phones, and phone cameras have given us a feeling of simplicity in their operation and how they see. Technology has made the phone camera simple to use, even for a child.
As the future progresses and vehicle cameras gain even better resolution and become higher in pixels, there will still be requirements regarding aiming and calibrations after changing the mounting location. The new software algorithms and AI software being developed for use with these cameras will improve the operation of these safety systems in new vehicles arriving every day. The need to correctly work with and aim these cameras or any sensor will not change. We need to look at them not just as sensors but as part of an entire system. We may not think a step or a procedure in the repair process matters, but it does.
Article Credit to BodyShop Business.
What is your view on the importance of the proper calibration of ADAS systems. Let us know in the comments below. Also, if you found our content informative, do like it and share it with your friends.
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