ADAS calibration: the new must-have in every modern workshop

Driver assistance systems - ADAS (Advanced Driver Assistance Systems) for short - are ubiquitous in modern commercial vehicles. Emergency brake assist, lane departure warning, adaptive cruise control and blind spot monitoring are standard equipment in new lorries. However, many workshops underestimate this: After numerous repair and maintenance jobs, these systems need to be recalibrated. If calibration is not carried out, the assistance systems will work incorrectly. This results in potentially fatal consequences for road safety and considerable liability risks for the workshop. The calibration specifications of the respective vehicle manufacturer and the type approval frameworks of the EU Regulation 2019/2144. Specific calibration obligations and intervals are always based on the specifications of the respective vehicle manufacturer.

This article explains why ADAS calibration in the workshop is becoming a mandatory service for every modern commercial vehicle workshop, what equipment you need and how calibration fits into the workshop process. Anyone who has already invested in modern Truck diagnostics has also created the technical basis for this next step.

ADAS calibration is a technical procedure. It allows you to precisely readjust driver assistance systems such as Emergency Brake Assist, Lane Keeping Assist and adaptive cruise control after interventions. Since EU Regulation 2019/2144, it has also been mandatory in all new lorries and thus determines road safety throughout the entire operation.

ADAS systems use cameras, radar sensors, lidar sensors and ultrasonic sensors to detect the vehicle's surroundings. These sensors are aligned with the utmost precision. A deviation of just a few millimetres or fractions of a degree therefore has consequences: An emergency brake assistant triggers too late or not at all, a lane departure warning system generates false warnings or the adaptive cruise control calculates incorrect distances. If you want to delve deeper, you can also find further information in the article on preventive maintenance.

EU Regulation (EU) 2019/2144 makes a number of assistance systems mandatory for new commercial vehicles. This will significantly increase the number of vehicles with systems that require calibration. The majority of newly registered commercial vehicles already have several ADAS systems. For workshops, this means that Calibration expertise is becoming an increasingly important part of the service portfolio.

The question of liability is clear. If a garage carries out a windscreen replacement and does not recalibrate the front camera, it is liable for malfunctions of the emergency brake assist. This also applies to lane work, wheel alignment and bumper work where radar sensors may be affected. Documenting the calibration carried out is therefore not only good practice, but also a legal defence.

ADAS sensors are calibrated using two fundamentally different procedures. Depending on the system and manufacturer, these must be used individually or in combination.

During static calibration, you position special targets and calibration plates at a defined distance and exact alignment in front of the vehicle. The vehicle is positioned on a flat surface. The diagnostic software then sets the sensors to calibration mode and they realign themselves using the targets. In practice, static calibration typically takes 30 to 90 minutes per system. It also requires a dedicated space in the workshop with sufficient clearance (at least 8 to 10 metres in front of the vehicle).

Dynamic calibration takes place during a test drive. Firstly, the diagnostic software puts the sensors into learning mode. The system then calibrates itself using real road markings, signs and traffic situations. The journey must take place under defined conditions: dry road surface, good visibility, defined speed range and sufficient driving distance (in practice 15 to 30 kilometres). Not all systems support dynamic calibration. Front cameras therefore almost always require static calibration as a basic setting.

You will need the following components for an operational calibration workstation:

A universal calibration frame for commercial vehicles must be adjustable in height and width to cover different vehicle types and sensor positions. It is therefore the central mechanical framework of every calibration workstation. The targets, on the other hand, are manufacturer-specific: a basic set typically includes targets for the most common makes (Mercedes-Benz, MAN, DAF, Volvo, Scania, Iveco). New targets for other makes can be added on a modular basis as required. This makes the calibration workstation a scalable investment that grows with the range of brands supported.

Not every diagnostic device is capable of ADAS calibration. You therefore need modern multi-brand diagnostic platforms with manufacturer-independent ADAS support. Alltrucks partner workshops work with the Alltrucks multi-brand diagnostics - the Alltrucks KTS Truck V3 (from Bosch with Knorr-Bremse integration) for future vehicle generations. The makes and sensor types covered depend on the current software version. You also need to update the software regularly, as manufacturers are constantly introducing new generations of sensors and calibration protocols. You should therefore calculate an ongoing software update budget right from the start. This is the most important prerequisite for ensuring that the platform covers the current generation of vehicles for years to come. Heavy-duty coverage also depends on the OEM and the calibration equipment available. We will be happy to discuss which configuration suits your company.

Often overlooked, but crucial: The floor in the calibration area must be level, as a slope of more than 1 degree can distort the calibration. You should therefore check the evenness using a spirit level or a rotating laser. It may then be necessary to level the floor or use levelling plates. You must also align the vehicle exactly at right angles to the calibration frame. Laser alignment systems are available for this as stand-alone components or solutions already integrated in the calibration frame.

The list of work after which an ADAS recalibration is required is more extensive than many workshops assume. The most important triggers:

• Windscreen replacement: Front camera sits behind the windscreen - static calibration always required
• Front/rear bumper: Radar sensors are often located in or behind the bumper
• Track work and wheel alignment: Chassis changes influence the sensor alignment
• Steering work: Steering angle sensor must be relearned after adjustment
• Chassis work: Changing the vehicle height influences the camera angle
• Mirror replacement: Side cameras and blind spot sensors in mirror housings
• Software update of the control units: Can reset ADAS parameters
• Tyre change with changed dimension: Influences wheel speed sensors and distance calculation

The calibration of driver assistance systems is first and foremost a technical obligation resulting from the manufacturer's specifications and the liability situation. At the same time, it is an additional service area that requires specialised equipment, trained personnel and a high level of care. How this can be categorised in business terms - hourly rate, cycle time, capacity utilisation - depends heavily on the company, the brand mix and the regional environment. If you want to delve deeper, you can also find more information in the article on Workshop profitability Further information.

Calculation example with disclosed logic (purely illustrative, not a commitment): If, for example, 5 calibrations per week are performed at 1.5 hours each, this results in 7.5 calibration factoring hours per week and, extrapolated over the year, around 390 hours. However, whether the equipment will pay for itself depends on the actual calibration volume, the enforceable hourly rate and the make mix in the region. Please contact us for specific categorisation in your own company. We will go through capacity utilisation, neighbouring competition and equipment level together.

ADAS calibration in the workshop is not yet available in every independent commercial vehicle workshop. Those who offer the service in-house therefore keep the repair process together and do not have to outsource calibration steps to external service providers. For fleet customers, this can also be a relevant factor when choosing a service partner. However, the extent to which this is the case depends on the regional environment and the make mix.

Each manufacturer has its own calibration protocols, targets and software requirements. For independent workshops that service several brands, this means that cross-manufacturer solutions are mandatory. Modern multi-brand diagnostic devices also support all relevant commercial vehicle brands in one platform - however, the coverage varies depending on the manufacturer approval. Before purchasing, you should therefore check which makes are supported and how quickly updates for new models are available.

Static calibration requires 8 to 10 metres of free space in front of the vehicle - often a challenge in existing workshop halls. However, there are several possible solutions: firstly, the use of a separate hall or a covered outdoor area. In addition, flexible calibration frames that you can stow away after calibration. Finally, a time equalisation outside the main working hours.

You must document every calibration carried out: Date, vehicle identification, calibration performed, measured values before and after calibration and the name of the employee performing the calibration. This documentation is therefore your safeguard in the event of liability and at the same time proof of quality for the customer. Modern diagnostic systems also generate the calibration report automatically. Therefore, make sure that it is saved and handed over to the customer.