Automotive Sensors 101 for Collision Repair

By Kiran Wagh | May 23, 2024

Sensor technology is one of the fastest-moving sectors in modern car and truck manufacturing. Most sensing devices are used in advanced driver assistance systems (ADAS). Each year, car manufacturers invest in developing automotive sensors, from cameras to oxygen sensors. The ever-evolving innovations in all types of sensors in automobiles present unique challenges for collision repair facilities.

Why Body Shops Need to be Automotive Sensor Experts

Diagnostics, repair procedures and recalibration for cars with sensors must be precise. The correct way to repair or replace a sensor is to rely on up-to-date OEM resources like SUN Collision Repair Information. Incorrectly repaired or calibrated automobile sensors can increase the likelihood of an accident.

While accurate car sensor repair is a safety issue, keeping more collision repair jobs like ADAS and sensor repair in-house is a winning move. Less outsourcing means less repair markup, tighter quality control and a healthier bottom line. When you invest in the most up-to-date repair information, you keep more work for the shop, decreasing turnaround time and overhead.

Car sensors are integral to modern vehicle safety, from rear bumpers to engine blocks, and windshields to brakes. With constant advancements, body shops can expect to encounter new and existing sensor repairs regularly.

Types of Sensors in Cars and Trucks

So, how many sensors are in a car? According to Tech Briefs, modern vehicles can have 10 or more cameras for ADAS alone. Automotive World estimates an average of between 60 and 100 sensors in total. Many of these types of sensors in cars can be unfamiliar to repair technicians, while a few may be business as usual.

Engine Sensors

Most engine sensors will be familiar to any collision repair shop that performs mechanical repairs. Each sensor typically throws a code, triggers a check engine light or initiates other alerts.

Mass Air Flow Sensor

The MAF, or mass airflow sensor, is essential for optimal engine performance and is controlled by a vehicle’s computer system. Because the system calculates the air density of the engine, a malfunctioning airflow sensor can affect fuel economy and cause a car to go into limp mode. Airflow sensors have been around for a while and are becoming more interconnected and complex as time goes on.

Oxygen Sensor

The oxygen sensor (O2 sensor) monitors the level of exhaust gasses to create the optimal oxygen mix. The sensor compares the readings to the ambient air to determine whether the engine runs lean or rich. Depending on the results, a vehicle’s computer adjusts fuel metering and emission levels. Symptoms of a faulty oxygen sensor include poor fuel economy, a rough-running engine or a failed emissions test.

Spark Knock Sensor

The spark knock sensor monitors how fuel burns to prevent fuel ignitions that could damage the engine. When a spark knock sensor isn’t working correctly, rings, rod bearings, head gaskets and other engine components are at risk. Besides a code or dashboard warning light, a faulty spark knock sensor could cause a loss of power to the engine and higher fuel consumption.

Coolant Sensor

A coolant sensor’s job is to monitor the temperature of the engine’s coolant. However, a vehicle’s computer system relies on the coolant sensor data for a range of information, including determining the flow of the EGR (exhaust gas recirculation), spark advance, etc. Common symptoms of a faulty coolant sensor are overheating, a rough idle and reduced engine performance.

ADAS Sensors

ADAS technology uses many types of sensors in cars to prevent and minimize collision severity. From automatic parking to fatigue detection, these advanced sensors focus on vehicle safety. Because ADAS technology is becoming increasingly complex, collision repair facilities must learn to diagnose, repair and recalibrate sensors.

Many ADAS failed sensors won’t present immediate or apparent signs like engine sensors. Collision technicians must rely on scan tools and up-to-date OEM repair information to determine if a sensor needs repair or recalibration.

Radar Sensors

Radar sensors, which use short-range, mid-range and long-range radar, have been a staple since the inception of ADAS. Because radar has a limited detection field, vehicles often have multiple radar sensors for a more comprehensive field of view. Recently developed sensing technology may soon make radar sensors obsolete, but collision shops will continue to encounter and service them for decades.

Ultrasonic Sensors

More advanced than radar sensors are ultrasonic sensors, using sound waves to calculate the distance to objects. While ultrasonic sensors have a short effective operating range of about six to seven feet, they are typically used for more precise, low-speed systems. From parking assistance to blind-spot monitoring, these types of automobile sensors are cost-effective and reliable components that should continue to be a part of modern ADAS.

Cameras

Cameras will remain a preferred automotive sensor type for ADAS-equipped cars and trucks. While cameras may not have the reliability of radar or ultrasonic sensors in bad weather and low light (yet), their benefits make up for the deficiency. An ADAS camera’s ability to identify color, contrast and other minute details uniquely suits them to monitor and identify road markings, pedestrians and motorcyclists. Many ADAS use cameras and radar sensors together to provide a more comprehensive stream of feedback and analysis.

LiDAR Sensors

While this exciting sensor technology has yet to find its way into mass-produced vehicles, many manufacturers are betting on LiDAR as the future for ADAS. LiDAR (light detection and ranging) is used for everything from discovering lost civilizations in the Amazon to a catalyst for autonomous vehicle prototypes. This technology works like radar but uses lasers instead of electromagnetic waves to create the most complete 3D image of its surroundings.

LiDAR and other advanced sensing technologies on the horizon remain too expensive for use in ADAS. However, as the costs decline, these innovations will inevitably become standard vehicle equipment. Understanding the types of sensors in cars and preparing for the future is critical for your body shop’s success.

The Future of Automobile Sensors

Artificial Intelligence (AI) is already a significant component of advanced safety features and engine sensors and will become essential for sensors of the future. The increased use of AI in automobiles will take some getting used to for drivers and repair technicians. But the benefit of safer roads is more than worth the trade-off.

Imagine a driver nodding off behind the wheel. Current vehicle sensors can sense changes like lane drifting and alert the driver. A safer alternative would be a system that combines optical, physiological and other sensors to detect driver drowsiness. AI-powered sensors could identify eyes closing, slower heart rates, head movement and other indications of drowsiness.

The combined internal and external sensors would work together to identify dangers and intervene. This intervention could include automatically decreasing speed, pulling over and calling for assistance. These scenarios may seem like science fiction, but whether you’re ready for it or not, AI will be standard equipment in the near future.

According to Juniper Research, driving with AI-powered systems will soon be as natural as turning the key and buckling up. Here are the key takeaways from their most recent research:

• The market for automobile sensors will grow to over $92 billion by 2026.
• Sensors in internal combustion engines will decline substantially.
• Over 33% of consumer vehicles manufactured in 2026 will be electric.
• Current initiatives are striving for 100% electric auto sales by 2030.
• Most sensor growth will be in vehicle automation and ADAS.
• Cameras will continue to be the sensors of choice until LiDAR becomes cost-effective.

The inevitable all-electric future will require new types of sensors and technology. Electric vehicles (EVs) must have a system to measure the SOC (State of Charge) relative to total capacity. They also require monitoring for the SOH (State of Health) in the gradual decline of battery performance.

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Embrace Technology for Automotive Sensor Repairs Today and in the Future

The line between mechanical and collision repairs has all but disappeared, making up-to-date OEM repair information a necessity. Vehicle technology advancements like ADAS and car sensors aren’t slowing down. Body shops need the most advanced collision repair information to keep up with vehicle manufacturers. A decade or so from now, we’ll probably look back and be amazed at how we ever functioned without sensors.

Modern collision repairs require modern tools for safer, more accurate repairs in less time. When your body shop invests in SUN Collision, you receive industry-leading training and support.

SUN is your partner for meeting the challenges of vehicle technology today and in the future.

Call 877-840-1973 for additional information or request a free demo today!