vehicle technology & collision repair trends - 2018 · • if damaged, complete part...

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Vehicle Technology & Collision Repair Trends - 2018

Director, Industry Technical Relations Jason B. Bartanen

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I-CAR Vision

Every person in the collision repair industry has the information, knowledge, and skills required to perform a complete, safe, and quality repair for the ultimate benefit of the consumer.

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Topics • Advanced Driver Assist Systems and Collision Repair

Diagnostics • Advancements in Steel and Aluminum Vehicle Structures

and the Implications on Collision Repair • Advanced Joining Technologies Required for Collision

Repair • The I-CAR Repairability Technical Support Initiative

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Collision Repair Diagnostics

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Collision Repair Diagnostics

• Malfunction Indicator Lamps (MILs). • Pre-repair scanning (Pre-scan)

– help identify hidden damage – help identify related and unrelated damage – improve cycle time

• Post-repair scanning (Post-scan) can help ensure the vehicle is returned to the customer with no DTCs.

• Calibration/aiming is essential for complete, safe, quality repairs.

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OEM Position Statements

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Advanced Driver Assist Systems (ADAS) • Collision Warning • Adaptive Cruise Control • Lane Departure Warning • Lane Keep Assist • Blind Spot Detection/Monitoring • Active Park Assist • 360° Cameras • Collision Braking

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Collision Braking (cont’d)

2022 – Standard Feature

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Collision Braking (cont’d)

Courtesy IIHS

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Autonomous Vehicles

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ADAS Challenges • System Identification • Parts Location • Damage Analysis and Inspection • Part Replacement • Calibration/Aiming Requirements • Module Programming • Post-Repair Inspection

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ADAS Opportunities • Diagnostic Capabilities • Cycle Time Improvements • Tools and Equipment

• Essential tool? • Expertise

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Calibration and Aiming Requirements • Varies by vehicle make/model • Static test • Dynamic test • Scan tools • Special equipment or tools

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Calibration and Aiming

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Calibration and Aiming (cont’d)

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Calibration and Aiming (cont’d)

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rts.i-car.com

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I-CAR Repairability Technical Support (RTS) (cont’d)

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I-CAR Repairability Technical Support (RTS) (cont’d)

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I-CAR Repairability Technical Support (RTS) (cont’d)

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I-CAR Repairability Technical Support (RTS) (cont’d)

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I-CAR Repairability Technical Support (RTS) (cont’d)

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I-CAR Repairability Technical Support (RTS) (cont’d)

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I-CAR Repairability Technical Support (RTS) (cont’d)

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Steel Advancements

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1,500 MPa Steel

Advanced Design and Materials –Honda Accord

4-Door Models

1 Front Inner Upper Pillar

2 Center Pillar Upper Stiffener

3 Side Sill Stiffener

4 Inside Sill Reinforcement

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Advanced Design and Materials – Honda Civic Sedan

1,500 Mpa Steel Rear Frame Rails

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Mazda - Mazda6

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I-CAR Repairability Technical Support (RTS) Website i-car.com/rts

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• No straightening • No sectioning • If damaged, complete part replacement is the only

option • Squeeze-Type Resistance Spot Welding (STRSW)

is the preferred method for part replacement • Where two-sided STRSW is not possible, MIG

Brazing is required • MIG Brazing should not be used in place of

STRSW where accessible

Honda 1,500 MPa Steel Repairability Guidelines

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• Non-fusion joining process • Smaller heat-affect zone

• Minimizes the loss of strength with HSS & UHSS

• Less damage to zinc coating • Capillary action

MIG Brazing

Text

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• Key to strong joint • Draws the filler metal

into the joint • Similar strength

characteristics to GMA (MIG) welding, with less heat-affect zone

Capillary Action

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• MIG welding machine • Short circuit • Pulse-spray may be

required • 100% Argon shielding

gas • Electrode wire

• CuSi-A • CuAl-A1 • U-shaped drive rolls

Equipment

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• Honda • General Motors • Jaguar/Land Rover • Volkswagen • More to follow • Only use where

specified

OEM MIG Brazing Recommendations

MIG Brazed Slot Welds

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MIG Brazing Joints

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MIG Brazing Joints - Honda

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• Fit-Up • Do NOT overclamp • Good root gap

• Weld-Through Primer • I-CAR published, inter-

industry developed and vetted best practice

Set-Up and Preparation

Good Bad – No Root Gap

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I-CAR Best Practice: MIG Brazing Prep These recommendations apply only when there are no instructions from

the vehicle maker. MIG braze panel preparation best practice include: • Remove paint coatings in the weld area. • Leave as much of the zinc coating intact as possible. Leaving the zinc

coating intact, it will aid in corrosion protection of the weld area. The presence of zinc in the weld zone does not affect the weld puddle formation or create excessive porosity.

• Follow OEM corrosion protection guidelines after MIG brazing is complete.

• The use of weld-through primer for MIG brazing is not recommended. Weld-through primer creates severe porosity in the weld zone; especially when making plug welds, two-hole plug welds, and slot welds. Even with the weld through primer removed from the weld area, as you would during GMA (MIG) plug welding, weld-through primer creates an unstable arc and extreme porosity for MIG Brazing.

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MIG Brazing Hands-On Skills Development

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Aluminum

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Dedicated Repair Area • OEM Requirements Vary

– Aluminum Dust Concerns • Galvanic Corrosion • Minimal Potential For Explosion

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Rivets

Self Piercing Rivet

Blind Rivet

Solid Rivet

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Rivet Bonding Hands-On Skills Development

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Mixed-Material Vehicles

Aluminum Steel

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I-CAR Repairability Technical Support

RTS Portal rts.i-car.com

Industry / OEM Linking Pin

OEM / T&E TACs

Repairability Summits

Repairability Technical Support

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RTS Portal (rts.i-car.com)

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RTS – OEM Information

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RTS – OEM Information (cont’d)

© 2016 I-CAR I N T E R – I N D U S T R Y C O N F E R E N C E O N A U T O C O L L I S I O N R E P A I R 49

RTS Analytics

35,373

25,656

47,600

34,434 33,270 33,341

30,346

34,662

53,051 55,313

0

10,000

20,000

30,000

40,000

50,000

60,000

2015 Q1 2015 Q2 2015 Q3 2015 Q4 2016 Q1 2016 Q2 2016 Q3 2016 Q4 2017 Q1 2017 Q2

RTS Users

141,174

107,022

167,499 157,807

175,455 166,185

152,636

178,022

273,231 274,614

0

50,000

100,000

150,000

200,000

250,000

300,000

2015 Q1 2015 Q2 2015 Q3 2015 Q4 2016 Q1 2016 Q2 2016 Q3 2016 Q4 2017 Q1 2017 Q2

RTS Page Views

2017 Monthly Average – 91,308

2015-17 Total – 1,793,645 2017 Monthly Average –

18,061 Users

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Thank You!