Commercial Vehicle Workshop May 2023

REGULARS

EMISSIONS

14 Diesel Technic’s Lars and Kevin are back. This month they are tackling a troublesome NOx sensor.

17 Eminox serves up some tasty thoughts on EATS.

20 Morris Lubricants’ Adrian Hill is a clever man. He goes to great lengths to explain the valuable role played by oils, lubricants and additives in keeping emissions in check.

ROAD SAFETY/VEHICLE SECURITY

22 New research from Brigade Electronics reveals there is still much work to do in changing attitudes towards vehicle safety technology.

25 Lights, cameras, action! Three fleet operators talk about the value of onboard video and recording systems.

29 A pain in the glass. Victoria Evans, Esprit Windscreens, argues for better performance testing for repair equipment.

32 ZF’s engineers adopt their inner crash test dummy to make urban bus driving safer.

34 Road safety –what’s new?

36 Alarming thought – don’t let thieves steal your catalytic converter. CATrack has the solution.

WORKSHOP MANAGEMENT

38 Logistics expert McCulla has its workshop and fleet management in perfect harmony thanks to Fleetway.

40 TruTac reveals its new module that promises to increase workshop productivity.

Editors

JOHNNY DOBBYN

JOHN LEVICK

workshop@cvwmagazine.co.uk

Editorial Assistant

FREYA COLEMAN

Group Editor

KIERAN NEE

Digital Manager

KELLY NEWSTEAD

Digital Assistant

LYDIA PROCTER

Senior Account Manager

ALEX DILLEIGH

Group Manager

ROBERT GILHAM

Graphic Designer

GEMMA WATSON

Group Production Manager

CAROL PADGETT

Subscriptions

Commercial Vehicle Workshop is a business magazine for companies and individuals involved in all aspects of commercial vehicle servicing.

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Copyright © 2023

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AIN’T THAT SOMETHING!

Artificial Intelligence or AI is either a scary or wonderful thing, depending on your point of view and maybe your age. Those of us old enough to remember Stanley Kubrick’s and Arthur C Clarke’s film 2001: A Space Odyssey, will recall HAL, the computer with a human personality. HAL didn’t behave kindly towards his human masters.

Fifty-five years on and AI is reaching into every part of our lives, no more so than in our industry. It might be in its infancy but a quick stroll around last month’s Commercial Vehicle Show reveals its growing influence in vehicle technology. Several exhibitors were showcasing systems that feature AI to improve road and vehicle safety.

CameraMatics was launching its i-DAS (Intelligent Driver Assistance System), that uses deep learning algorithms to make sense of data, continually scanning for pedestrians, hidden road users and cyclists. It’s also capable of filtering out road furniture, ensuring that drivers are only alerted to genuine risks.

Brigade Electronics had Radar Predict, a system that works by constantly gathering object detection data such as the speed, direction, acceleration and turning rate of a vehicle using radar technology. It also collates vital information from the cyclist or other vulnerable road user such as distance from the lorry and speed, and then calculates the point of collision with vulnerable road users and warns drivers of any potential risks.

It's all clever stuff and making an important contribution to accident prevention, driver wellbeing and overall safety. But AI won’t stop there, that’s for sure.

There’s already lots of research going on looking at different applications of AI in HGVs, such as fuel consumption prediction, emissions estimation, self-driving technology, predictive maintenance, remaining useful life (RUL) and time between maintenance (TBM) using various machine learning and deep learning methods.

According to a recent article in Internet of Vehicles for Intelligent Transportation System ‘heavy-duty vehicles use about 18% of the energy and 17% of the petroleum used in the United States. Apparently predictive maintenance can save about 8–12%’. It goes on to conclude that ‘a small change in transportation emissions and fuel economy, lowering maintenance time, and improving the safety of drivers can have outsized effects and significant global impacts on climate and natural resources’.

So, the scope for improvements, greater efficiencies and cost savings is huge and we are barely scratching the surface. Whether we like it or not, or even whether we are aware of it, AI will be lurking somewhere in the background. You’ll only realise it when you’re changing an apparently serviceable oil filter – your AI-driven maintenance programme predicts that it’s on its way out. Better do as it says.

Happy reading!

“...it’s all clever stuff and making an important contribution to road safety...”

Academy opens its doors

Award winning fleet solutions provider, Rivus has achieved IMI approval for its Rivus academy, a purpose-built training centre for LCV and HGV technicians.

The academy opened on 28 February 2023, following formal approval by the Institute of the Motor Industry (IMI). The purpose-built training centre is an extension of Rivus’ existing service, maintenance, and repair garage in Leeds. It comprises a classroom style training facility, capable of delivering knowledge and theory-based learning for up to 16 people, as well as a fully equipped training workshop for practical training and assessment under test conditions. The academy has been designed to deliver IMI-approved hands-on training for LCVs, including ICE, hybrid and fully-electric vehicles, as well as HGVs.

Courses for all

James Haydon, Technical Training Manager at Rivus comments: “This is a really exciting development for Rivus. The team has worked hard to get us to this point and we’re very proud of what we’ve achieved so far. The site and all our training content has then been assessed and approved by the IMI and we have now achieved IMI approval to deliver our own in-house training.”

Initially Rivus will focus on delivering one- and two-day courses for IMI Levels 1, 2 and 3 in electric/hybrid vehicle awareness, routine maintenance and system repair and replacement, as well as the IRTEC large commercial vehicle inspection licence.

LCV buyers out in force

According to figures released by reseller BCA, LCV values averaged £9,851 in February 2023, with sustained buyer demand keeping values firm as the strong start to the year continued.

Sold volumes improved compared to January with values slightly down on last month at £9,851. Performance against price guides improved sharply to 105.7%, a rise of 3 percentage points, month on month.

With a slowly improving economic outlook, latest reports suggest business confidence has improved amongst SMEs and this is likely to be helping to drive demand within the used LCV sector.

BCA’s weekly valuation reports show that average values were relatively steady throughout February, following a steep climb earlier in the year, suggesting that supply and demand are currently well balanced.

Stuart Pearson, BCA COO UK, commented: “Following a good start for the

used LCV sector in January, we have experienced more of the same in February with robust price performance and rising volumes of vehicles sold. Also, with the economic landscape starting to look a little brighter and improved confidence levels amongst small businesses, we expect used LCV values to remain fairly resilient for some time.”

He added: “While there has been an improving picture in the new LCV sector for a number of months, it will be some time before we see any significant volume of younger vans reaching the used market. We’re also entering the third anniversary period of the first COVID lockdown when there was minimal activity in the light commercial sector for a few months, and that means a potential dearth of three-yearold stock until the summer. Taking all these factors into account, it is likely the marketplace for LCVs will remain competitive for some months to come.”

Totalkare gets behind BTRC

The British Truck Racing Championship has teamed up with workshop equipment experts Totalkare who will provide the race series with a range of vehicle lifts and heavy-duty workshop equipment at all seven meetings this year.

As part of the deal fans of the BTRC will see the Totalkare logo appear across podium backdrops and promotional materials at all the events. Steve Thomas, Truck Sport UK director, said: “We’re delighted to have partnered with Totalkare for the new season. When looking at the wide range of

products that they offer, it is clear that it is a perfect fit for not only the Championship but those that follow us as well.”

“Over the past few years Totalkare has grown rapidly through the expansion of our product portfolio,” added Steve Braund, marketing manager for Totalkare. “We’ve put a lot of effort into increasing brand awareness and see our new partnership with BTRC as a logical next step in building on this strategy.

“There’s a lot of synergy between the brands and we can’t wait to get trackside with our market-leading equipment and watch the action unfold!”

Continental rolls out advanced tyre management

Continental is promising even more functionality with the launch of its Advanced package for its recently upgraded ContiConnect 2.0 tyre management solution.

“The Advanced package now lets customers capitalise on all the benefits of tyre management,” explains Dushyanth Rajagopal, product manager digital solutions. Every tyre can be tracked individually, whether it is on the vehicle or in the warehouse. There is a digital twin of each tyre in the system, complete with article number, meaning the customer always knows which tyre is fitted on which vehicle and in which position. Pressure and temperature, tread depth and tyre condition can also be recorded and monitored. The newly developed second-

generation ContiConnect sensor relays information on distance travelled, allowing fleets to keep track of tyre mileage at all times. The charge level of the sensor battery is also displayed within the system.

In addition to the exact data readings, ContiConnect 2.0 Advanced users also receive alerts for tread depth and temperature, recommendations for tyre pressures, as well as reminders when vehicle inspections are due. “This paves the way for an even more efficient, straightforward, sustainable and forward-looking form of fleet management. ContiConnect 2.0 Advanced offers haulage companies the advantage of greater fleet efficiency through reduced costs and time savings, as maintenance and workshop appointments can be planned in advance," adds Rajagopal.

Granville gears up with new look

Oil and lubricants specialist Granville has undertaken a corporate rebrand that sees it leaving behind the familiar rectangular red and blue tram tracks and introducing what it says is a more flexible, modern and recognizable logo.

The new design features an equilateral hexagon within which sits a stylized G that is split into three parts to symbolize quality, value and customer service. It will be paired with the traditional Granville logotype as a nod to the company’s heritage.

As part of the rebrand the G icon will change colour to reflect the placement and colour scheme of the product on which it is placed; the Performance range of oils will have a gold colourway, while the trade-oriented Hypalube portfolio will have a silver icon.

Shape of things to come

In tandem with the redesign, the company is also introducing a new look and feel to its Hypalube range of oils. The new gun metal trade bottle has a distinctive appearance with strong lines and sharp corners and chunky easy-togrip handle. Labelling has been upgraded with colour coding to reflect the contents – fully synthetic, semi synthetic and mineral grades – as well as the winter/weight ratio of the oil.

Sauna in the cab!

Everybody loves an April Fool and this year’s best has to be the news from Scania that it was launching a new driver-focused Sauna-Series cab.

According to the company’s press release ‘each Sauna-Series truck comes equipped with an infrared heat cabin, designed to use minimal energy to heat up and doesn't require extraction fans to remove steam. It means you can enjoy the sauna while watching TV, reading a book, doing admin or while having a nap.’

Additionally, the truck manufacturer claimed that its ‘research and testing showed that drivers who used the sauna were more productive than their other counterparts, with drivers claiming they could drive for an additional 4.5 hours a day – 'no sweat'.’

Anybody thinking that it might be all true would have been disappointed by the last line of the announcement that said that the first 250 people registering an interest in the new cab would receive a luxury bathmat for free - normal retail price £2,304.01!

Power tool bundle up for grabs!

We are a bit late to this one but there’s still plenty of time to enter Sealey’s tool competition and a chance to win a great power tool bundle worth an amazing £725!

All you have to do is visit www.sealey.co.uk and go the competitions page where you can see the SV20 series power tool bundle, which could be yours. Alternatively get a copy of the latest Tool Promotion catalogue which has entry details inside. The competition is open until the 30th June so get cracking.

Retreading plant renamed

Bandvulc’s Ivybridge plant has been rebranded as a Continental LifeCycle production facility, in a move that sees it become more closely aligned to Continental’s Stöcken LifeCycle plant, which produces hot-retread tyre.

The plant focuses on hot retreading for the UK market, with Bandvulc tyres being designed and manufactured in Ivybridge. The site also produces ContiRe branded

New vans in demand

The UK new light commercial vehicle (LCV) market grew for the third consecutive month in March, rising by 17.3% to 47,634 units, according to the latest figures published by the Society of Motor Manufacturers and Traders (SMMT).

Traditionally a large volume month due to the new number plate, the growth was amplified by comparison with a weak March last year, when chronic supply chain shortages drove the market down by -27.6%. Demand was up across all segments, apart from vans weighing up to and including 2.0 tonnes, down -24.6%, reflecting broader trends which favour larger units. The second most popular weight class, vans weighing greater than 2.0 to 2.5 tonnes, rose by two thirds to 66.3%.

Above Par

North-east-based fuel supplier, Par Petroleum, has recently enhanced its status by achieving Driver and Vehicle Standards Agency Earned Recognition.

The independently owned business, which has been operating for over thirty years, has a fleet of 27 road tankers and works in partnership with the retail, marine and oil sectors, supplying bulk fuel and nonhazardous liquid products nationally. The company also supplies fuel and lubricant

tyres in partnership with the Stöcken plant.

Tony Mailling, head of hot retread production EMEA and plant manager of ContiLifeCycle Ivybridge and Stöcken, said: “Although the name has changed, the values on which Bandvulc was built will continue. The facility is undoubtedly one of the most technically advanced retreading plants in Europe and our people are a testament to this achievement. In becoming a LifeCycle site, Ivybridge’s position is strengthened as part of the wider Continental manufacturing network.

“With the Bandvulc tyre range set to grow further during the next 12 months, staff and customers can rest assured that the brand will continue to be a major player in the Continental tyre range.”

Registrations of vans weighing greater than 2.5 to 3.5 tonnes increased marginally by 4.9%, as market share declined to 64.3%. Double digit growth did, however, continue in the smaller volume pickup and 4×4 utility segments, rising by 29.3% and some 183.4% respectively.

As a result, 87,272 light commercial vehicles have been registered in the first quarter of 2023, up 17.4% against Q1 last year, in the best start to the year since 2021’s 97,356 units. However, despite the rise in demand, the quarter remains -15.1% off pre-pandemic 2019. Commenting on the figures, Mike Hawes, SMMT chief executive, said: “A solid first quarter of growth for the van market is a positive outcome, given the importance of vans in keeping Britain’s businesses on the move.”

products to homes, farms and businesses. Operations director, Stuart Hardy, commented: “We are thrilled to be awarded Earned Recognition. Our team works very hard to maintain high standards across the business and this is testament to their efforts.”

TRAFFICNEWS

Daily boost

The shopping list includes chassis cab models equipped with luton boxes, single and crew cab tippers, dropsides, and tool pod tipper bodies, highlighting the huge range of applications for the Daily. An impressive 1,154kg payload and 3.5-tonne towing

capacity will enable Dawsongroup customers to complete even the most demanding of missions.

Supplied by Northern Commercials, the IVECO Daily models are powered by a 140bhp 2.3-litre diesel engine, balancing good fuel economy

with a strong 370Nm of torque. Many of these vehicles will be working with construction and utility companies, so taking advantage of the Daily’s new durable manual gearbox was an ideal choice. Clutch endurance has been improved by 18% versus the previous model while gearchange motion is even more precise with free play reduced by 50%. This added robustness also results in 350,000km oil change intervals.

Top of the range specs

Safety and comfort are essential for Dawsongroup, with every IVECO Daily featuring the residual-boosting business trim level which features as standard manual air conditioning, cruise

control, fog lights and electrically heated and adjustable door mirrors. Also standard are hi-adaptive memory foam seats that reduce pressure peaks by up to 30%. This boosts comfort behind the wheel and reduces fatigue. They also feature ‘city mode’, a system that minimises steering effort for operators as they take full advantage of the Daily’s classleading turning circle.

For more information the IVECO Daily models

International supply chain company Dawsongroup plc has placed an order for 270 3.5-tonne IVECO Daily vans to give its customers further choice in 2023.

VANAWAYS

Independent vehicle supply specialist Vanaways has teamed up with leading convertor CoolKit to give customers a one-stop shop for topquality temperature-controlled vans.

Cool bit of kit

Operators can now take advantage of Vanaways’ speedy, simple ordering system – in conjunction, if required, with CoolKit’s online configurator for insulated body options – to create the perfect refrigerated van.

Chill out

“The partnership is yet another extension of our service to busy van operators,” said Vanaways

sales director Paul Cox.

“By working in partnership with CoolKit we aim to make the acquisition process for these specialist vehicles as quick and easy as possible, while ensuring that conversion work is carried out to a guaranteed high standard.

For more on Vanaways and CoolKit, WWW.RDR.LINK/VAY002

Krone hits the right note with operator

KRONE TRAILERS UK

Krone Trailers UK is helping Southern Van Lines, a theatre and music tour specialist, to gear up for a busy year as the sector continues to bounce back after COVID.

Southern provides transport and logistics for some of the biggest names in the arts as well as for festivals, conferences and corporate events. Based in South London, it runs a fleet of 15 tractor units, 40 trailers and five rigids.

The company required some more 4m trailers to assist on contracts into Europe, carrying

high value soundboards and other sound equipment. It turned to Krone UK which supplied two Krone Dry Liners.

In tune

Director Charles Colley said: “We have had Krone trailers on the fleet since 2018 and really like them. They are good value and the drivers like using them. We needed some more 4m trailers and Krone was our first port of call. It was able to offer much quicker delivery than some of its competitors, which was important to us as we need these trailers for the

busy spring and summer season. They were also competitively priced which always helps.”

The Krone trailers also fit in perfectly with Southern’s truck livery. “Krone paints them in the Jamaican Blue shade which is a great fit with our own metallic blue colour scheme,” added Charles. “We also appreciate the extra security features like the additional locking bar across the rear door handles.”

For more on Krone trailers, WWW.RDR.LINK/VAY003

DAF makes it a Shaw thing

DAF XG+

Macclesfield-based Bolshaw Industrial Powders Ltd is making one driver’s day after taking possession of a new DAF XG+ from Motus

Commercials DAF – Stoke-onTrent. That lucky driver is Martin Shaw, a diehard DAF fan, who’s driven a succession of its vehicles over the years.

Martin explains: “I personally really like DAFs and have driven a number of DAF models in my career. The driver comfort is much better than the rest of our fleet.”

Jonathan Bolshaw, director of Bolshaws, adds: “The decision behind which truck to buy is mainly down to driver preference. Martin previously had the DAF XF but we try to give drivers the very best truck we can so now, with bigger and better cabs available, we chose the DAF XG+.”

The DAF XG+ 530 FTN is a rear-steer tractor unit, featuring Hyva tipping kit. It has a microwave, DAF digital vision system (camera mirrors), and additional Kelsa light bars. The new truck will be used for tipping work, but it will mainly be delivering Bolshaw’s products with a curtain sider trailer.

For more on the DAF XG+, WWW.RDR.LINK/VAY004

DISTRIBUTOR RECAP

Prime time at Roadlink

Roadlink International has expanded its product offering to include Prime Line, the new Brembo aftermarket range of brake discs for commercial vehicles.

The new range of brake discs features many of the technical formulas developed and patented by the group’s research and development centre, with specific technologies and adaptations to match the characteristics of heavy-duty vehicles. These include the use of a special cast iron alloy, exclusive pillar venting technology and a co-casting process. All this leads to greater heat dissipation,

superior resistance to thermal cracking and an increase in the life of both the brake discs and pads, even in extreme conditions.

A full range of stock is available directly from Roadlink’s central UK distribution centre and customers are provided with added reassurance as all

products in the range come complete with full 2-year warranty.

For more information

WWW.RDR.LINK/VAY005

WAI to go with revamp of heavy industrial rotating electrics

As part of its commitment to putting its customers first, WAI has unveiled a range revamp in its leading heavy-duty starters and alternators product portfolio.

Now with over 740 references in the range, WAI’s heavy duty alternators and starter motors cover popular vehicle makes including Mitsubishi, MAN, Mercedes Benz, Dodge, Isuzu, Renault, Scania and Ford.

The revamp includes part numbers 30129N for DAF LF, 19637N covering Atego, 19795N

to fit Scania and 12387N for Actros, which are expected to be fast moving parts.

The company claims that its customers have experienced a 60% reduction in warranty returns versus their former remanufactured product offering from competitors. With a 24month warranty on all rotating electrics, WAI products will give

technicians peace of mind and total customer satisfaction, it says.

The revamped heavy-duty alternators and starter motors are available now at its extended stockholding facility at the company's head office in Bognor Regis, West Sussex.

For more information

WWW.RDR.LINK/VAY006

KEV joins IAAF

KEV Ltd, a wholesaler and manufacturer of aftermarket components for the commercial vehicle (CV) market, has become a member of the IAAF.

The company supplies high quality components and truck and trailer parts for heavy duty vehicles.

Commenting on its membership, director Ugur Kizikoglu said: “We’re honoured to become a member of the IAAF and we hope to build longlasting relationships with other members, whilst showcasing

equality and transparency. We have a coherent vision to take our brand to the next level of the automotive parts sector, through co-operation with professional partners to execute challenges, as we foster an environment of collaboration.”

For more information

WWW.RDR.LINK/VAY007

OPPORTUNITY NOX

Back by popular demand Diesel Technic’s parts specialists and video stars, Lars and Kevin, tackle a NOx issue on a Renault Trucks Premium and consider what can affect the sensor.

During a main inspection of a Renault Trucks Premium, including an exhaust emission test, the vehicle's emissions control light flashes. Lars and Kevin carry out further investigation to reveal that the NOx sensor is playing up. According to Lars, this is possibly indicative of a failure in the wiring which is affecting the NOx sensor.

As a first step, the duo check the connector, which does not show any obvious defects such as oxidation. Next Lars checks the PINs of the NOx sensor, which also look flawless. After the cable also shows no chafing or other damage, the pair decide to remove the sensor in order to examine it more closely for possible causes of failure. While Kevin takes care of the sensor, Lars tests the cable with the multimeter. For this, the wiring diagram is needed – unless it is a newer vehicle. In that case, one is partially guided through the test. When measuring, one PIN

is connected to the control unit, the other PIN is connected to the cable. This way you can check if the wiring harness is defective and so causing communication problems. Since the sensor is CAN bus controlled, the two CAN lines must also be tested.

The sensor and the cables to the control unit are found to be in good condition on the outside, so the professionals suspect the fault to be inside the NOx sensor and so consider a replacement.

Fault finding tips

The function of the NOx sensor is to measure the nitrogen oxides in the exhaust gas stream. The results are analysed and passed on to the control unit. Furthermore, this sensor regulates the AdBlue injection, ie. the injection of urea into the exhaust gas stream, in order to comply with the EURO5

standard and to avoid environmentally harmful gases. A distinction must be made here between vehicles in which a NOx sensor is installed upstream of the catalytic converter to measure the nitrogen oxides. There are also vehicles with a NOx sensor installed after the catalytic converter. This checks the function of the catalytic converter.

In order to restore the vehicle to full working order, Lars and Kevin install a new NOx sensor. This is followed by the readout of the fault memory and the final exhaust emission test.

To make everyday life easier for others in the workshop, the two have a few practical tips on hand which might be worth considering when faced with similar issues to the above. The biggest problems usually lie in outdated software or in the choice of sensor which is not vehicle-specific. In the latter case, the chassis number is helpful.

In addition, scorched cables indicate thermal overload. Sufficient cable ties for correct cable routing can help here. A bluish discolouration of the sensor head also indicates thermal overload. Possible causes include problems with combustion or in the exhaust gas flow. AdBlue deposits, on the other hand, often have their origin in a defective metering unit or non-functioning control system. Oil residues on the sensor can possibly be traced back to a defective turbocharger.

Further hints and tips with regard to the NOx sensor can be found in the duo’s workshop video and on the Parts Specialists YouTube channel: ps-web.tv.

What's wrong? Thermal overload – sensor head colored bluish. Possible reason: too high temperatures. Combustion or exhaust flow problem.

What's wrong? – Thermal overload –cable scorched. Possible reason: the cable was in the exhaust gas flow or the cable was not routed correctly.

What's wrong? Broken pin. Possible reason: incorrect plug connection.

What's wrong? Defective sensor head. Possible reason: external force.

What's wrong? Oil on the sensor. Possible reason: defective turbocharger.

THE EXACT FUNCTIONING OF THE NOX SENSOR IS EXPLAINED IN THE PARTS SPECIALISTS VIDEO, AS ARE THE DIFFERENT VARIANTS:  WWW.RDR.LINK/VAY008

Start to disassemble the NOx sensor

NOx sensor in situ in the engine bay.

ZERO AMBITION

It seems there is barely a week passes by without news of how the UK and beyond is going to meet the ambitious net zero targets pertaining to our vehicles. With the Euro 7 targets being confirmed just a few weeks ago, thoughts are now turning, in the commercial vehicle world, as to what the impact will be, and how fleets will be able to meet those targets in the required time frame whilst balancing costs.

Zero emission fleets in the UK

Just a few months ago there was the news that over £200m of Government funding would be given to launch the world’s largest

fleet of zero emission HGVs to UK roads. As part of the plan, it outlined strategies to eliminate fossil fuels from HGV haulage to help to reduce delivery costs and protect consumers from rising fuel prices in the long term. Furthermore, as part of world leading pledges made by the Government at COP26, it stated it would ensure all new HGVs sold in the UK would be zero emission by 2040.

Whilst this is a valuable step to achieving environmental objectives in the future, there is also the very serious question of how we make existing vehicles compliant with the latest emissions regulations, now.

© Eminox in production

Dr Dave Phillips, engineering director, Eminox, explains what is being done to assist fleet owners and managers to achieve emissions compliance, and what the future looks like as the journey to net zero continues.

“...it stated it would ensure all new HGVs sold in the UK would be zero emission by 2040...”

Emissions solutions supporting the transition to a greener future

This is where robust and reputable exhaust aftertreatment systems (EATS) come into force. Delivering a reliable and costeffective option on the journey to net zero, retrofit solutions offer a way of upgrading fleets to achieve current Euro 6 equivalent legislative standards.

By reducing nitrogen dioxides (NOx) and particulate matter (PM) levels generated through vehicles’ exhaust systems, public health is protected, and air quality is improved making the vehicles emissions safer for those exposed to them.

Simply, EATS technologies help ensure fleets are reliable and agile and removes the emphasis from the costly process of having to buy new just to become emissions compliant. This is because successful emissions compliance does not have to mean replacing an older HGV or fleet, it’s about finding ways which best support your business, and this can also mean finding tangible solutions to achieve the same end goal whilst balancing time and cost efficiencies.

What the future looks like

In the shorter term, the official estimates of Euro 7 emissions improvement for trucks and buses, over and above the current Euro VI standard, puts NOx reduction at 56% and exhaust particulate at 39%. This does, however, need to be put into context in relation to the engine out emissions, and, by that measure, the potential emissions reduction is more like an extra 2-5 percentage points.

Beyond that, what is clear, is there is still a place for the internal combustion engine, albeit powered by alternative fuels. These fuels will include hydrogen, ammonia, methanol, e-diesel, biodiesel, and fugitive methane. Many of these alternative fuels are reliant on one common element, hydrogen. Without an abundance of hydrogen from low carbon sources it is not possible to synthesise low carbon ammonia, methanol, or e-diesel.

Whilst this all may seem a little daunting, it is reassuring to know Eminox is prepared for Euro 7 and will continue seamless supply of its EATS to support current requirements across all transport applications, whilst driving forward research and collaborative projects.

Finding the balance of driving forward emissions regulations, and not wasting what we have already, must be a primary consideration and this is where emissions technology solutions are the real game changers in delivering the best possible emissions standards, protecting public health, and improving air quality now, and in the future, no matter the vehicle type or fuel source.

“...successful emissions compliance does not have to mean replacing an older HGV or fleet...”

SMOOTH OPERATORS

In the world of road transport, the path to reduced emissions is a challenging one, but new technologies and the latest innovations continue to deliver significant improvements. However, there are many pieces to this ‘emissions’ jigsaw and each must be in place, for the true benefits to be realised.

Since the 1990s, continued legislation has driven vehicle emissions down and down, but to achieve this, engine and exhaust system modifications have had to be made. A variety of emission reduction technologies have been introduced to control the levels of NOx gases and particulate matter (harmful solid debris in the exhaust gas stream). The use and continued effectiveness of these systems have always depended strongly on the quality and performance of the lubricants used.

NOx gases can be controlled using Exhaust Gas Recirculation (EGR) and selective catalytic reduction systems (AdBlue). EGR creates a severe engine environment, with spent exhaust gases being directed back into the intake manifold. This reduces the amount of free oxygen available to convert free nitrogen in the air to NOx compounds. However, the side effect is incomplete combustion, which creates a large amount of abrasive soot.

Soot is not only abrasive, but also affects the flow properties of the oil. Without the correct level of lubricant performance, the engine will experience accelerated wear and oil thickening, which could lead to catastrophic failure. Correctly formulated engine oils control wear and thickening due to soot and will allow the engine to run at optimum efficiency, helping to reduce emissions.

Catalyst for change

The SCR (AdBlue) systems rely on the effectiveness of a catalyst fitted to the exhaust system. AdBlue, a solution of urea, is sprayed into the exhaust gas stream and is carried into the catalyst, where a chemical reaction takes place to remove NOx gases by creating nitrogen and water vapour. However, when the engine oil lubricates the compression rings, valve stems and valve guides, a small amount of lubricant is burnt, releasing sulphur and phosphorous from certain compounds.

As the engine runs, these elements find their way into the catalyst and poison the active sites where the reaction takes place, making the catalyst unusable. Engine oils must be formulated correctly to ensure the additive chemistry provides suitable levels of wear protection without affecting the catalyst. A poorly functioning catalyst will not only be unable to control emission levels, but engine management systems may put the vehicle into reduced power mode (or limp mode) until the situation has been remedied.

Diesel Particulate Filters (DPFs) are

installed in the exhaust system to catch particulate matter (soot) and to prevent it from entering the atmosphere where it can cause health and environmental issues. Sensors monitor the working pressure across the unit and when it drops to a defined value, a regeneration cycle is initiated. This usually involves unburnt fuel entering the unit, causing a temperature spike that oxidises the soot (solid) to carbon dioxide (gas). Carbon dioxide flows out and the unit is good to go again.

As mentioned previously, a small amount of lubricant is burnt during this process, and this creates a metallic ash that is swept into the DPF. However, the metallic ash that is generated remains behind and eventually the DPF will be unable to reach normal pressure ranges. Again, the vehicle will click into reduced power mode.

Using the correct engine oil with the correct formulation will protect the engine components, and also ensure that the DPF has the best possible service life. When the DPF is working at its optimum levels then particulate emissions are controlled more effectively.

To reduce emissions even further, efforts have been focused on improvements in fuel efficiency. New engine hardware architectures, designs and technologies are emerging that embrace multiple innovations.

Adrian Hill, technology manager at Morris Lubricants outlines just how critical the role of engine lubricants is in the fight to keep emissions down but engine performance up.

“...correctly formulated engine oils control wear and thickening to due to soot...”

There’s no doubt that engine downsizing, in terms of the number of cylinders employed, will continue. Eight-cylinder engines, with the odd exception (such as Scania), have already been moved down to six cylinders in numerous cases and with the adoption of variable geometry turbochargers, to give tailored boost depending on demand, power outputs have been maintained.

Variable valve timing helps to ensure maximum fuel efficiency under a wide range of loads and operating conditions. Different construction materials are starting to come into play. For example, steel pistons are being used to cope with higher peak cylinder pressures and allowing the top compression ring to be moved closer to the crown, reducing the crevice volume where burn inefficiencies can occur.

Fuel for thought

On top of these modifications, the aftertreatment devices are continuing to improve in design and effectiveness. Two stage AdBlue injection aims to improve NOx conversion, relying on a tailored engine oil formulation to ensure catalyst longevity. DPFs are removing even smaller particles and will remain effective longer by using the correct type of low ash engine oil.

Another strategy to reduce emissions is to improve fuel efficiency. If less fuel is used, then emissions are also reduced. Improvements in fuel efficiency can be made by using engine oils that produce thinner oil films in the bearings and where the compression ring travels along the cylinder liner area. These thinner oil films result in less drag and therefore offer more useable energy that can be used by the wheels.

To ensure that component integrity is not compromised, these thinner engine oil films are fortified with polymer chemistry to ensure there is no metal-to-metal contact. Polymers are essential when formulating 5W-30, 5W-20 and 0W-20 engine oils for the commercial vehicle sector. The modern heavy-duty diesel engine is complex and is still evolving. These new architectures, technologies and fuelling strategies produce real world emission reductions, but they will only achieve this if they are fitted with new generation engine oils, which are as critical as any other component.

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VEHICLESAFETY: A WAYTOGO

Brigade, who introduced the reversing alarm to the UK back in 1976, has been at the forefront of road safety for over 40 years. Well known for its aftermarket solutions for heavy goods vehicles and mobile plant, the company recently commissioned an indepth survey of transport operators across a range of disciplines. The aim was quite simple: to get more of an insight into the reasons they use technology on their vehicles, how they have enhanced

operations and safety, and what features influence their decisions to invest.

Those surveyed comprised third-party logistics companies and own account operators (80%), with the remainder being made up of public sector, municipal waste and others.

Technology gap

Despite over half of respondents saying that vehicle safety technology had improved driver safety behaviour, and half reporting that they had seen a reduction in insurance premiums, a whopping 32% claimed that they did not have any technology fitted and did not plan to do so in the next year, despite DVS star rating requirements increasing to three stars in 2024.

Out of those responding, 54% said the fitment of camera systems/digital recording had improved driver behaviour.

A total of 50% said safety technology had prompted a reduction in insurance claims, with 32% seeing a drop in incident reporting and 21% seeing evidence of an increase in fuel economy.

Overall the main reasons for the installation of systems were a desire to improve fleet standards, reduce insurance costs, improve driver behaviour and comply with the Direct Vision Standard.

New research commissioned by Brigade Electronics brings to light the drivers behind investing in and installing fleet safety technology. CVW takes a closer look at the findings.

Blind spots

The nearside blind spot is the biggest area of concern for 58% of respondents, followed by the rear blind spot at 20%, and 8% say it is the two feet in front of the truck between the window and ground.

When asked what important features were essential for future camera monitor technology, 65% thought it was important or very important to integrate cameras with advanced driver assistance systems (ADAS) – for example lane departure warning, collision warnings, and pedestrian detection.

Emily Hardy, Brigade’s UK marketing manager commented: “Seeing and analysing the thoughts of industry professionals on road safety is always fascinating and it is good to see, amongst some, a wider adoption of life-saving technology and a better understanding of the benefits.

“However, the results do reveal that there is a long way to go. Aside from the cost saving benefits, the reduction in road collisions is priceless, so it is startling to see there’s still so much education to do in the industry.”

New technology

This insight highlights the importance of developing cutting-edge road safety technology utilising AI, such as Brigade’s Sidescan Predict and Radar Predict.

Sidescan Predict – the latest evolution of Brigade’s ultrasonic technology – uses AI to determine potential collisions and warn the driver withsufficient timeforan intervention, whilst also minimising false alerts.

Radar Predict, meanwhile, is one of the most technically sophisticated products in the company’s portfolio and evaluates the behaviour of the vehicle as well as vulnerable road users.

In dangerous situations, it warns drivers with acoustic and visual alarms to avoid a possible collision. It also has the added advantage of only a two-hour installation time.

“This state-of-the-art system combines low cost, ease of installation and performance. The dual radar system uses an innovative combination of technology to detect road vehicles, objects and vulnerable road users to predict if a collision is likely to occur, before instantly alerting the driver to potential dangers,” explained Hardy.

“Our researchrevealed thatsafety concerns are clearly a major priority to operators. Our latest range of products help meet that demand and we are proud to do our bit in utilising the latest technology to protect cyclists and other vulnerable road users.”

Brigade believes HGV drivers need a combination of direct and indirect vision and other cutting-edge safety equipment, such as sensor and audio technology, for optimal safety. Currently its portfolio includes ultrasonic obstacle detection, white sound reversing alarms, camera systems, live digital recording devices and artificial intelligence-based systems.

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“...65% thought it was important to integrate cameras with ADAS...”

Safety cameras are an essential tool in fleet management, providing fleet managers with a valuable resource for monitoring driver behaviour, reducing accidents, and improving overall safety.

CVW examines how three fleet managers have deployed various systems to maximise their fleets’ performance.

THE CAMERA NEVER LIES

With safety cameras installed in commercial vehicles, fleet managers can monitor driver performance and identify areas for improvement, helping to reduce the risk of accidents and minimize liability costs. In addition to providing an objective record of accidents and incidents, safety cameras can also act as a deterrent to dangerous driving habits, helping to prevent accidents before they happen. With the ability to review footage in real-time and receive alerts when unsafe conduct is detected, fleet managers can take swift action to ensure the safety of their drivers and the general public.

In fact, some public authorities are likely to prescribe safety cameras for that very reason. In a move that shows how safety cameras are now an accepted part of any safety regime, Transport for London (TfL) has suggested that the Progressive Safe System (PSS) that comes into force in October 2024 will require mirrorreplacement camera monitoring systems (CMS) to be fitted in order to eliminate any remaining blind spots at the nearside.

TfL regulations to be introduced from October 2024 state that all HGVs over 12 tonnes must be minimum ‘3 star’ rated under its Direct Vision Standard, which rates production line HGVs for the standard of visibility from the cab. Those that do not meet this standard will need to retrofit a PSS to their vehicles in order to obtain an HGV safety permit. Without this, it is illegal to enter and operate in Greater London and the

penalties are £550 for the operator and £130 for the driver. The PSS requirements have yet to be decided as consultation has only just ended but should be known by summer 2023.

Live feed

Meanwhile fleet managers have found safety camera systems a useful addition to their toolkit, one that they are prepared to invest. Enva, a waste management and resource recovery solutions provider, has recently upgraded its safety camera system to take advantage of live streaming technology. The company has been using safety cameras for over five years to enhance driver safety and provide evidence of incidents on the road. The move to live streaming provides even greater protection for Enva's drivers,

allowing the fleet manager to remotely access live footage from any camera on any truck. This technology enables Enva to manage its vehicles more effectively by providing live GPS tracking and location data, as well as updates on camera status.

“It has proved invaluable to us,” Alan Jackson, Enva’s fleet maintenance supervisor with responsibility for Scotland, commented. He opted for the streaming technology developed by Durite, known as Durite Live. “We decided to move to Durite Live to provide quicker access to that footage and even better protection for our drivers. This could be a collision or even something as simple as providing proof to a client that we had visited their site on a specific date and time to collect waste.”

Camera systems can also be tailored to fit specific purposes and industries. For example, London-based waste specialist J O’Doherty Haulage needed a higher definition camera system that would give their drivers and fleet managers all-round vision of their vehicles.

“We wanted the new system to give both our drivers and fleet managers all-round vision of the vehicle and have the option to add on more cameras if needed,” Matthew Tyler of J O’Doherty Haulage said.

His solution was to buy more than 100 eight-channel HDD DVR (hard disk drive digital video recorder) kits from Durite. Compared to a four-channel camera system, the eight-channel kit increases visibility, particularly when monitoring vehicle operations such as tipping.

Host of applications

To ensure complete coverage, one camera is mounted looking out from the cab, while a dome camera monitors the inside of the cab. Another camera is mounted at the rear to assist the driver when reversing, and more cameras on each side of the vehicle provide full coverage when turning.

The high-definition camera system and its strategic placement offer drivers better vision and control, improving safety and reducing the risk of accidents. It also provides fleet managers with real-time information that can help optimize fleet management and improve operational efficiency. The adaptability of the camera system highlights how safety cameras can be adapted for different purposes to suit a company's specific needs.

Another haulier looking to address specific vision and monitoring challenges is Joda Freight, a UK-based logistics and haulage services provider that faced challenges in vehicle safety and security. Technical director Neil Tullett said: “The camera safety system needed to provide photo and video evidence in the event of an accident, attempted fuel theft or vandalism, as well as help us deal with false insurance claims and scammers.”

The answer was a 4G-enabled 4CH DVR monitoring system integrated with a side scan detection system with left turn alarm, which is a requirement for DVS. The system, which was customised to Joda's needs by Durite, includes a customised external alarm that activates the DVR and starts recording automatically, while at the same time the alarm

goes off to deter would-be thieves.

As artificial intelligence becomes more sophisticated it will be incorporated into the safety camera systems available, providing ever more data that will enable fleet managers to maximise the potential of both their fleet and their drivers.

SCREEN TEST

The late 1980s and early 1990s heralded an influx of windscreen repair products to the UK market. This was great for customers; they could now get their screens repaired instead of replaced, saving them money, as well as providing a new market for repairers and garages. However, with new players, came new concerns; fundamentally, were the repairs safe, and who could you trust to do them? Into this discussion came the British Standards Institute (BSI), which looked into whether repair was safe, whether it worked and ultimately put guidelines into place to assist in selfregulating the system, to give customers the ability to choose a product that had passed the standard set down by the BSI.

Changing standards

Two standards were created, BS AU 242a to govern what size of damage could be repaired and where on the screen, and BS AU 251 to govern the quality of the repair system. This performance test mirrored ECE R43, the performance test of a new windscreen and although it wasn’t a compulsory standard, customers knew that if their repair was carried out under BS AU 242, this meant the repair system had also been tested under BS AU 251. Ultimately this meant their customersthe driver and passengers - were as safe as possible in in the event of an accident.

The BSI committee was reconvened in 2019 to consider the effect of ADAS on windscreen repair, and throughout

“...were repairs safe and who could you trust to do them?...”

Cracking time: note that this windscreen is beyond repair.

Windscreens are expensive to replace but repair offers a cost-effective solution to cracks and chips. However, some repair methods are more equal than others when it comes to efficacity. Victoria Evans, managing director of Esprit, puts the case for more rigorous standards to be applied to windscreen repair.

numerous meetings between 2019 and 2022 it was eventually decided that BS AU 251 would no longer apply, that any repair system could be fit for purpose if the manufacturer stated it to be. The old 242a was updated to BS AU242b:2002 which came into force in March 2023. Crucially, this new standard no longer has a performance aspect; repair equipment and resin no longer has to be performance tested to claim the British Standard.

There is value in the new standard. It reduces the number of repair zones to two, restricts repairs directly in front of ADAS/HUD technology, increases the record keeping requirements of repairers and formalises training requirements for technicians. These are all valuable and useful guidelines, and should reassure customers that their repairer is trained, is keeping records and is repairing in areas of

the screen that won’t interfere with vital ADAS technology.

However, what the standard doesn’t cover, is arguably the most important part of the repair; what repair equipment is being used to actually carry out the repair, and does it work? Fundamentally, a technician can keep records and train as much as he or she likes, but if the equipment used doesn’t work, or fails a month later, or worse, in an accident, then all the guidelines in the world won’t help. The new standard also puts the onus of compliance onto the technician or the repair organisation and away from the equipment manufacturer.

The tests laid down in BS AU 251 were numerous, and designed to ensure that in an accident, the windscreen would behave in the same way as a non-damaged screen (the EC R43 test). Tests didn’t just check the clarity and strength of the screen (although this was tested), the screen was also tested to see what would happen if something impacted it or if a head collided with it from the inside. Under the new standard, none of this is tested. Customers have no idea how the repairs will affect the underlying structure of the glass, or how the screen will be affected in a collision.

Structural versus cosmetic

This lack of performance testing is worrying. Windscreen repair, when done well and with tested equipment, is a safe and economic solution to breaks and windscreen chips. However, if there is no performance test, there is a risk that there will be a race to the bottom, with cheap, ineffective repair kits coming onto the market. With the price of everything rising, customers can’t be blamed for trying these cheaper repair options, but they need to be able to differentiate between the cheap kits that might just provide a cosmetic repair effect, and those that are repairing deeply within the screen, restoring the structural integrity of the screen and ensuring that drivers are kept safe in an accident. If customers don’t have this, the risk is they will move away from repair as a whole, which would be detrimental to the many repair kits that would very likely pass a performance test.

Testing times

At Esprit, we were disappointed when the performance test was removed from the British Standard. Our aim has always been a race to the top, we believe performance standards are how we ensure that standards across the industry are maintained, and customer confidence is sustained. Following the removal of the performance test, we are working with TUV Rhineland to develop a rigorous new testing regime aligned with

“...we are working with TUV Rhineland to develop a rigorous new testing regime...”

ECE R43 that both meets and exceeds the standards set down by BS AU 251, ROLAGS, AFNOR and AS/NZ 2366.2. We hope these tests will be fully available within the next three months.

Although Esprit has been instrumental at developing these new independent performance tests with TUV, they aren’t our tests; they’ll be open to any business who manufactures or distributes repair equipment, and we would welcome and encourage any manufacturer or distributor to undertake these tests with the worldrecognised TUV Rhineland.

We believe this is how we will maintain the confidence of customers and insurance companies; independent performance testing will raise the standards of the industry as a whole and ensure that customers know that the product they’re using works safely and effectively - surely a benefit to the whole industry.

PUTTING THE BRAKES ON ACCIDENTS

CVW hears how ZF engineers literally became test crash dummies in a bid to improve bus passenger safety.

Every driver who has suddenly had to hit the brakes while driving will know the impact of these forces on the body. While the occupants of a car can rely on seatbelts to help counter this forward momentum, what happens when it’s a city bus full of people? Unaware of the impending collision ahead, without seatbelts and many standing, passengers are left vulnerable.

“Coming to a sudden full stop might avoid a crash, but passengers can still get injured from falling over and bumping into each other,” explains Philipp Helmich, head of vehicle dynamics product lines with ZF’s commercial vehicle solutions division. “Using our experience and knowledge, we have developed a pioneering new collision mitigation system (CMS) for city buses. By connecting the radar and camera with a central processing unit and braking system, City bus CMS addresses the clear and pressing demand for ever-higher levels of safety in city traffic.”

Offering active braking to help avoid frontal collisions with other road users, including vehicles, bicycles and pedestrians,ZF’s city bus CMS system helps counter the adverse impact of

brakingmomentum on passengers. Helping reduce the risk of accidents and injuries both inside and outside of the bus, ZF’s solution is the industry’s first manufacturer independent CMS specifically engineered for city bus applications.

Testing times

Balancing safety requirements was crucial to the development of City Bus CMS. The key question was how much braking force is necessary to maximize the chance of avoiding a crash while keeping occupants

inside the bus safe? To figure this out, advanced driver assistance systems (ADAS) experts from ZF went above and beyond the usual testing protocols. At the company’s test track in Jeversen, Germany, the team strapped on safety harnesses and helmets on board a city bus. Testing, documenting and evaluating the experience at different speeds and braking forces from a passenger perspective helped to determine how much deceleration intensity is acceptable at a given speed.

“After that, we had to transfer these findings into algorithms for the system’s control software,” points out Jakob Schmidt, customer requirements engineer with ZF’s CVS division. “What we did was integrate

Camera Sensor

Radar Sensor

Image Processing Module

the data with ZF’s advanced braking capabilities that are precisely calibrated to the vehicle’s speed and weight. That way, we achieve a seamless interaction between the ADAS and braking system.

“Braking pressure is carefully applied across the braking profile, making passengers far less likely to be jolted and put off-balance,” adds Schmidt. “Designing the breaking profile like that minimizes the adverse effect on the passengers while still providing the best possible support for the bus driver in these challenging situations.”

Emergency braking assistance systems for city buses are not currently regulated and need a different approach to help safeguard passengers from injury during emergency braking. The complex and highly dynamic urban traffic environment also makes it difficult to implement. ZF’s solution tackles these issues head on. Signals from the sensing units are transmitted and calculated to make

“intelligent” braking for the city bus possible. A slight brake easing after initial pressure helps give standing passengers the opportunity to hold on and prevent a fall before brake force is again increased. Offering significant value for manufacturers and fleet customers, ZF claims its city bus CMS represents a major step forward in enhancing bus safety for passengers and road users alike. Helping mitigate hazardous traffic situations in the complexity of an urban environment requires sophisticated situational analysis,

including advanced object detection and classification. Building on ZF’s safety systems expertise, the CMS draws on its latest OnGuardMAX technology with specific features and functionalities that are tailored to city bus applications.

Combining the data from its state-of-theart camera and radar provides continuous analysis of the traffic situation. If an impending collision is detected, the system can issue a forward collision warning (FCW) and automatically apply the brakes to help mitigate or avoid an accident.

The system is compatible with both electric and internal combustion engines. Having already secured business wins from leading bus manufacturers, ZF will initially launch its city bus CMS in Europe and, ultimately, plans to roll the system out worldwide.

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PREDICTING THE FUTURE BRIGADE

Brigade’s Sidescan Predict is the next generation of ultrasonic detection, according to the company. By analysing speed, direction and acceleration of both the vehicle and detected object and differentiating between static and moving objects, the Sidescan Predict algorithm assesses the risk and calculates the likelihood of an impact.

Designed for rigid vehicles, Sidescan Predict instantly alerts the driver to potential dangers via a multi-stage in-cab visual warning system, according to the urgency of the situation, thus minimising audible alerts and false alarms. The system can be activated all the time when the speed is below 20mph, without causing driver overload and is not dependent on indicator selection for activation. Sidescan Predict sensors ensure full coverage down the nearside of the vehicle with a range of two metres and do not activate in relation to roadside furniture or stationery vehicles.

Brigade’s new side radar detection has been designed to improve safety on both articulated and rigid vehicles. Previously detection systems were fitted to the tractor unit, but the trailer was neglected due to the articulation causing false alerts.

Brigade’s new side radar detection can detect whether the vehicle has a trailer. It is predictive and only warns the driver if a collision is likely via a visual display in the cab. Side radar detects the truck turning, so indicator selection is not required to activate the system. It has a quick install time of approximately two hours, meaning less vehicle downtime.

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ARTIFICIAL INTELLIGENCE, REAL BENEFITS CAMERAMATICS

CameraMatics is promising to radically improve driver reaction times and blind spot visibility with the launch of what the company believes to be the most advanced AI-powered collision avoidance system on the market.

Fleet operators will be able to empower their drivers with i-DAS (Intelligent Driver Assistance System), which also includes DMS (Driver Monitoring System) to provide drivers with unparalleled awareness of vulnerable road users and distractions.

i-DAS features strategically placed blind spot detection and driver monitoring cameras, combined with in-cab display and speakers, to give drivers real-time warnings of hazards and collision risks. The system’s external AI cameras feature adjustable detection zones of up to 30m, providing perfect coverage of risk zones.

The system uses deep learning algorithms to make sense of the data, continually scanning for pedestrians, hidden road users and cyclists. It’s also capable of filtering out road furniture, ensuring that drivers are only alerted to genuine risks.

In low-speed, high-risk manoeuvres, where visibility is often at its worst and pedestrians and other road users more likely to be hidden in blind spots, i-DAS acts as the perfect Moving Off Information System (MOIS). At the same time, internal cameras monitor the driver’s head position and eyes to look for signs of fatigue or distraction, providing audible and visual feedback when risks are detected.

Video snapshots of any road incidents are automatically recorded and uploaded to the CameraMatics cloud, which enables rapid incident response and helps fleets to integrate evidence-based driver coaching programs.

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CAMERA SOLUTIONS IN A CLICK DURITE

Durite, one of the UK’s leading suppliers of camera solutions for commercial vehicles, has launched an interactive website designed to help fleet operators and transport managers easily select the optimum equipment to improve safety, remain compliant and reduce costs.

Based on research and customer feedback the company set about designing a new and simplified method for fleet buyers, managers and owners to find the right equipment for their individual business needs.

To this end, Durite’s new Logistics and Transport Operator support system features a ‘Kit Selector’ that uses a simple step-by-step process to quickly determine which products are best for each transport operation.

Listing a range of vehicle types: HGV, rigid, van, waste, PSV, emergency and construction, the Durite Kit Selector provides a one-click pathway to “All-inOne” solutions including safe manoeuvring, incident recording and livestream fleet management.

While offering the correct safety solution, the system simultaneously enables operators from virtually all transport sectors to ensure compliance with current regulations such as FORS and DVS (Direct Vision Standard).

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LOCK AND LOAD VANGUARD

The ULTI Bar, ULTI Rack and ULTI Lock ranges from Van Guard Accessories – which claims to be the “ultimate” ultimate van storage and security supplier – are designed to provide operators and garages with the ‘ultimate’ in storage and security for light commercial vehicles.

Easy install ULTI Bars are constructed from specialised anodised aluminium extrusion sitting on reinforced steel brackets. The ULTI Bar uses the ultimate combination of both materials and engineering techniques to maximise its sheer strength. ULTIRack+ features a sleek aluminium alloy design, made to measure foot packs, multi-use side channels and full width rear rollers, not to mention a cross bar system with T-slot rails. This is said to offer unparalleled tie down, load restraint and accessorising capabilities.

The latest generation of ULTI Lock van hooklocks feature anti-drill side plates, anti-bump hook design, anti-pick, bump, and drill cylinders and anti-snap lock cases. The company also offers trade van racking, rear door ladders and pipe carriers to allow for full accessorisation of LCVs for trades.

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ALARMING STUFF

Catalytic converters contain palladium, platinum and rhodium, which is twice as valuable as gold. Thieves either break the converter open to remove the precious metal component or sell the catalytic converter for recycling for up to £650.

“Converters can be stolen in less than two minutes and enormous losses are being borne by insurance companies and fleet operators, as well as the disruption and loss of revenue from vehicles being undriveable,” says John Rollins. Rollins is the co-founder and chief operations officer of CATrak Technologies, which is marketing CATrak, an anti-theft device specifically designed to deal with this issue.

According to him, CATrak is the only anti-theft device that notifies the owner of a theft in progress. The device not only sets off a deafening 140dB alarm – the equivalent to a gunshot going off in your ear – but notifies the fleet manager or owner on the GPS location of the targeted vehicle.

Scaleable solution

The system includes a CATrak module installed on the vehicle, along with a separately mounted alarm and custom cutdetect module (CDT). Any attempt to steal theconverter will involve cutting either the converter itself or its wiring harness. Once that happens, the alarm goes off and whoever is responsible for the vehicles is notified of the theft in progress via the CATrak app.

The CATrak was developed with fleet in mind so the app can be set up to monitor any number of vehicles, all uniquely identified. An unlimited number of users

Thieves targeting catalytic converters is a big issue for UK fleet operators. One US company claims to have an answer, so CVW asked its boss to talk us through it.

can use the app to 'keep watch' so, for example, the app could link to the gatehouse and traffic office, alerting staff on their control screens.

The CATrak secure portal enables an unlimited number of users, with various security functions, to investigate or notify security services and any preselected contacts of a theft directly via the app.

Rollins argues that this type of protection is far superior to conventional anti-theft devices. “Passive anti-theft devices rely on physical barriers such as

plates, cages and straps,” he says. “These devices slow thieves down but do not prevent them as thieves are increasingly proficient at removing barriers and using saws that cut directly through them. They also slow down vehicle maintenance because they usually need to be removed when you service or repair the vehicle.”

Despite the device being developed in the US, the company has decided to launch it in the UK because we apparently have a far worse problem – for once we are ahead of the US!

“We decided to launch in the UK as thefts are reported to be 10 times higher than in North America," Rollins explains. "Criminal gangs are targeting vehicle depots and that's why we've developed a system that allows each device with vehicle ID to be paired with the mobile app. Should a theft be attempted, any designated person can immediately see which vehicle is being tampered with, where it's located, and take immediate action to prevent it.”

More than 97,000 catalytic converters were stolen from the beginning of 2020 to 30 November 2022, according to OPAL, the National Intelligence Unit for Serious Organised Acquisitive Crime. There may well be a similar number of unreported thefts, so there are likely to be hundreds of thefts and attempted thefts a day.

The whole problem seems to prove the old saying that “no good deed goes unpunished” because the most desirable vehicles are the ones that are most environmentally friendly and comply with low emission legislation –

hybrid vehicles. Hybrid catalytic converters have a higher concentration of precious metals to start with but they are also used less than a full diesel or petrol-engine vehicle, so the precious metals corrode less and so are worth more. And that puts fleet operators in the front line, Rollins argues.

“Fleet operators are switching to low emission vehicles. This is not just because of the need to reduce carbon footprints –and the fact that petrol is now considerably cheaper than diesel – but more and more UK cities are introducing low emission zones,” he says. “Vehicles that are exempt from charges, like hybrids, have converters that are worth more, so criminal gangs now see company car parks and vehicle depots as easy pickings.”

Even trucks are not immune, according to Rollins – and not just because they are higher from the ground and so easier to

access. He points out that an oxidation catalyst can be integrated with the diesel particulate filter (DPF) and these are also being stolen for scrap.

“Even though HGV diesel catalytic convertors don't contain precious metals, they are a very expensive spare part that can cost up to £3,500 and may often be stolen to order,” he says.

Whether it is worth protecting an entire fleet with such a sophisticated device as the CATrak will depend on a lot of variables –where the fleet is kept, where it delivers and whether insurance premiums will reflect the lower risk, for example. Yet it is another weapon in the fleet manager’s armoury to keep the show on the road.

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“...more than 97,000 catalytic converters were stolen...”

COOL RUNNING

Temperature controlled logistics provider McCulla (Ireland) provides ambient, chilled and frozen logistics solutions throughout Ireland, the United Kingdom and Europe. Established over 50 years ago and operating from sites in Lisburn, Dublin and Mallusk, the company is leading a move toward environmentally friendly transport and runs vehicles fuelled with biomethane gas produced by the company’s own anaerobic digester plant.

McCulla first deployed software from Freeway a decade ago initially to build an asset register and manage workshop scheduling, and later it was extended to manage stores and purchasing. With the fleet expanding to 120 vehicles and 210 trailers and increasing moves toward digitisation, it embarked on a further stage of automation in January 2018.

At this stage the business realised Freeway could be used for more than just the fleet and was seen as ideal for use as a more general asset management system. So, other assets – everything from plant to warehouse racking –have been added to the system.

In the workshop, technicians were being equipped with tablets for paperless working. Rolled out in 2018, this has transformed the workshop and has been central to a programme to improve the management of compliance.

Meanwhile McCulla accelerated system integration work with Freeway seamlessly interchanging data with its Sage accounting software, its Mandata TMS traffic system and a driver mobile app. Now through the Freeway and Mandata connectivity, transport planners have an instant view of vehicle availability and if any of vehicles have any outstanding defects or scheduled workshop bookings.

The integrated driver app meanwhile is used for driver coaching, infringement sign‐off and defect report. The app interlinks directly into Freeway on all defects that are recorded during driver walk‐around checks. This means the workshop has immediate visibility of any defects so a supervisor can assess whether the vehicle can be used or not.

“Freeway is integrated with accounts, transport management and driver mobile

Keeping things chilled on the maintenance front is all important for logistics player McCulla. CVW finds out the secret of its success.

devices to provide a seamless flow of data. This not only eliminates paperwork and keying‐in but crucially it gives an instant view of workshop activity and schedules,” says Brian Beattie, operations director, McCulla. “It means everyone is always fully aware of the availability and status of every asset, 24/7 and that is genuinely transformational.”

Each technician has their own individual workshop tablet that creates job cards, defect fault and rectification against each job card. Freeway stores all records for all assets and has a planned maintenance schedule for each asset group.

“The main benefit we have seen since moving to this fully paperless process is better and easier management of compliance,” says Beattie. “All inspections, services, MOTs and fridge motor inspections are planned using Freeway, making

scheduling easier and more reliable because the potential for human error is removed.

“And because reported defects come through instantly to our vehicle technicians and planners, we are able to be proactive in rectifying them,” Beattie says. “This results in reduced downtime and better vehicle safety because we catch problems early. We avoid compliance failures because we can VOR a vehicle with a critical defect within minutes of the issue being discovered.

“We also have more data about our fleet’s health than ever before so we can track repeat defects on vehicles or components and we can better plan our fleet replacement strategy.”

McCulla has long been a pioneer in sustainability and one on the many assets

managed by Freeway is its anaerobic digester plant and associated equipment. This plant creates electricity and HGV fuel from food waste.

The business has also deployed Freeway for managing stores and for procurement; not just vehicles and parts but also across hundreds of items used throughout the business such as office consumables. The integration with Sage meanwhile sees invoice‐matched purchase order data pushed automatically from Freeway to Sage and matched to the relevant cost centres and nominal codes, removing the requirement for double entry.

Better visibility

“With real‐time data being freely interchanged we now have a very high level of visibility of the performance of the fleet and everything else we maintain and purchase,” Beatie explains. “That’s something we just didn’t have before. It means we can make much better informed decisions when it comes to optimising our resources and controlling costs.”

The implementation of Freeway software was managed by Genie Insights. The County Antrim‐based fleet technology company, which is Freeway’s partner in Ireland, has also supplied McCulla with solar panels to provide supplementary power to refrigerated trailers.

“...we can better plan our fleet replacement strategy...”

NEWMODULE MAXIMISES VEHICLEMAINTENANCE

TruFleet, the fleet management software developed by TruTac, was introduced three years ago, and now there is another new module, TruFleet Workshop. CVW finds out more.

When TruTac launched TruFleet it seemed quite comprehensive. Here was a tool, vehicle compliance and maintenance software, that seemed to cover all the bases. Transport managers could use it to plan, organise and control all aspects of day-to-day fleet and O-Licence management.

They could instantly see all planned maintenance events including inspections, MOTs, services, LOLER checks and repairs. They could even create bespoke entries for each operator’s requirements and view all weekly calendar events in detail on a single screen. It has proved popular too, according to TruTac managing director Jemma James. “Our TruFleet vehicle maintenance product has proved to be a great success and is

widely relied upon by fleet managers in the HGV and PSV sectors,” she says. “TruFleet brings efficiencies to day-to-day vehicle maintenance and helps to maintain compliance control.”

So why add TruFleet, yet another module? James says that the latest module enables fleet managers improve their dayto-day vehicle maintenance and compliance control and was developed in response to customer demand.

“Now, based on feedback from our customers, we have introduced TruFleet Workshop so busy fleet managers can create bespoke vehicle documentation, focus on running costs and generally tighten up all areas of resource and vehicle asset management,” she says.

The TruFleet Workshop module comes with a wide range of features that are tailored to workshop needs. Users can now create customised templates for vehicle inspections, repairs, servicing, MOTs, and associated running costs. The module also allows for electronic periodic maintenance inspections (EPMIs) that are easy to create and merge for servicing and inspections.

System integration

Each of these templates are fully customisable, easily edited, and cloned, and can be used for any fleet asset, including trucks and trailers. The module also includes an option for improving audit trail transparency by allowing operators to choose sign-off levels with up to three independent signatures, such as for the technician, rectification second signature, and manager's signature.

Furthermore, the TruFleet Workshop module is fully integrated with TruChecks and the TruTac driver application. This means that fleet managers can identify and log any defect while fully recording the audit trail from initial identification to rectification and sign off within the system. Costs can be logged against each asset for full control and visibility. The company says that it will release further costing enhancements over the coming months.

TruFleet Workshop, along with other TruTac compliance and data management software products for HGV, LCV and PSV

“..managers can create bespoke vehicle documentation...”

fleets will be demonstrated by the TruTac team at this year’s Microlise Transport Conference, on May 17th at the CBS arena in Coventry.

TruTac offers a one-stop shop of compliance products to aid fleet management and compliance control, including TruAnalysis, the full tachograph management system, TruFleet for improved maintenance planning and TruChecks for easier daily vehicle inspections. According to TruTac, more than 5,700 operators use its software products and the number is growing daily. TO

FEIN FOR NOW FEIN

Fein’s power tool portfolio has grown with the launch of the CG 15 compact angle grinder - the first of its class to feature a fully encapsulated, brushless FEIN PowerDrive motor. The tool’s powerful, yet efficient, 1500W motor and superior powerto-weight ratio allow the user to operate with more efficiency and for longer. The angle grinder has been designed with cost and longevity considerations in mind, requires fewer wearing parts, has longer service intervals and incurs lower maintenance costs throughout its life.

The CG 15 grinder also offers users extensive protection through a variety of safety features, including restart protection, kick-back check, jam monitoring and an efficient brake which brings the tool to a stop in less than two seconds.

WANT TO KNOW MORE?

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CITYMASTER IS ALL ABOUT TOWN BANDVULC

The new Citymaster 5 retread tyre for the bus and coach sector is Bandvulc’s latest tyre introduction. The company says the next generation Citymaster 5 majors on delivering exceptional reliability, durability and safety for operators of passenger carrying vehicles.

The new rubber features an all-new reinforced sidewall, developed exclusively for the bus and coach market. An extra layer of rubber compound has been added to the outer sidewall for greater protection against kerbing. The tyre also has a dimple indicator, moulded into the sidewall rubber in three places. This allows operators and technicians to easily see when a tyre has been 'scrubbed' enough to begin compromising its performance and should be considered for a change.

The high polymer rubber compound used in the Citymaster 5 has been designed to resist punctures and withstand the punishment of start-stop use. Both are vital to maintaining passenger safety and reliability of service.

Along with the added resilience afforded by the reinforced sidewall, the new tryre claims to have better handling characteristics through its solid shoulder design, a wide contact area to combat lateral forces and additional deep sipes to provide excellent traction and grip. The proven tread pattern is retained from the tyre's predecessor, the Citymaster 2, and is offset for noise reduction, with grooves designed to lessen the impact of any punctures.

WANT TO KNOW MORE?

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ADDITIVE A BIG PLUS FOR PRODUCTIVITY CROMAX

Cromax has introduced a new plastic additive - AZ9700. Formulated to improve the effectiveness of energy surfacers PS1081, PS1084 and PS1087 and the wet-on-wet nonsanding surfacers NS2081, NS2084 and NS2087, it is said to offer both flexibility and excellent adhesion when painting exterior plastic vehicle parts. The direct-to-plastic additive reduces process steps and products for the repair of plastic parts, boosting productivity by optimising the workflow of plastic repairs and increasing throughput.

AZ9700 is part of the ValueShade concept which delivers the optimal undercoat for every topcoat colour, for faster coverage and reduced basecoat consumption, enabling bodyshops to speed up processes and increase profitability.

WANT TO KNOW MORE?

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NEW LEASE OF LIFE FOR PSA HDI ENGINE IVOR SEARLE

Remanufacturer Ivor Searle has added the 2.0 litre PSA Blue HDi diesel engine for the Citroën Relay II and Peugeot Boxer III to its all-makes range of major units. The newlyadded Euro VI compliant direct injection engine covers 110, 130 and 160bhp derivatives of the popular Relay and Boxer vans built from 2016 to 2019. Costing up to 40% less than OE, the latest addition to the Ivor Searle engine range is suitable for six-speed manual versions of the Relay and Boxer, including models fitted with stop/start technology.

Built to exceed the BS AU257:2002 Code of Practice for remanufacturing engines, all Ivor Searle units are covered by a 12-month unlimited mileage parts and labour warranty. The company also offers free next day UK mainland delivery for stock items ordered before 3.30pm.

WANT TO KNOW MORE?

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SAND AND DELIVER MIRKA

In a bid to reduce clean up time and reduce costs Mirka is introducing a range of userfriendly, ergonomic, dust-free long fileboards (fairing boards) for filler, undercoat, and gelcoat sanding. The cleverly designed boards come in three different models and two different lengths: 1600mm rigid, 1600mm flexible, and 680mm rigid, to suit a variety of surfaces including flat, curved, large or small. They are said to be very effective when combined with Mirka Galaxy, Abranet, and Abranet ACE abrasive rolls, providing cutting-edge abrasion while virtually eliminating dust because of the long fileboards’ integrated dust extraction device that simply fits to a dust extractor.

WANT TO KNOW MORE?

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NOW, EAR THIS KNIPEX

KNIPEX ear clamp pliers (10 98 I220 and 10 99 I220) provide a simple and reliable solution for mounting 1-ear and 2-ear clamps on vehicles. With the ability to work with Oetiker system or similar clamps, the pliers are a versatile and durable tool.

One of the key features is the ability to mount clamps without causing damage to the press points on the ear clamps. This is especially important for applications where the integrity of the clamp is crucial to the performance and safety of the system. The slim head of the pliers also permits good accessibility in confined areas, making it easy to work in tight spaces. The 10 98 I220 version weighs just 350g and has dimensions of 220 x 50 x 21 mm, while the 10 99 I220 version weighs 345g and has dimensions of 220 x 48 x 20 mm.

Ideal for work on cooler and fuel lines, air pressure systems, compressors, and other applications where clamps are commonly used, the durable construction means the pliers are built to last and withstand the wear and tear of regular use. Made from high-grade special tool steel, forged and oil-hardened for added strength and durability, the pliers feature a comfortable grip, making them easy to use for extended periods of time.

WANT TO KNOW MORE? WWW.RDR.LINK/VAY027 GOTO

ROCKET PROPELS NEW LUBRICANT IN YOUR DIRECTION TETROSYL

Rocket TT is a multipurpose, highperformance, light gel super lubricant for all types of surfaces. Its crystalline wax film provides extended longlasting protection from corrosion and rust. It stops squeaks and lubricates moving elements, including locks, tracks, hinges, and handles, whilst also working to penetrate and release corroded parts, fasteners, seized nuts and bolts, cables and linkages.

It comes in a variety of sizes, including 100ml, 300ml, 450ml and a mega-sized 600ml aerosol can, with the 300ml, 450ml, and 600ml having a choice of either a traditional cap and manually applied straw or a 2-in-1 super tube, which means the customer can use the wide spray, precision spray or move the spray tube at an angle of their choice to get to a hardto-reach area.

WANT TO KNOW MORE?

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LONG NOSE PLIERS MAKE SHORT WORK OF JOBS LASER TOOLS

Grip, crimp, strip insulation and cut wires — all these functions are part of this new fully-insulated set of longnose pliers from Laser Tools (part number 8423). VDE-marked and manufactured to IEC 60900 standards for 1000vAC / 1500vDC live working, these pliers are part of Laser’s extensive range of insulated tools and workshop safety equipment designed for use on hybrid and electric vehicles.

These really are useful and versatile pliers: the long-nose jaws open to 95mm and the VDE insulated handles are equipped with slip guards. They are tough and robust, with strong plier body hardness of 42-48 HRC (Hardness on Rockwell scale C) and even harder cutting edges of 58-62 HRC for a long service life. Use them as crimping pliers for insulated and non-insulated crimp terminals and strip the insulation off 1.5 and 2.5mm wires. With generous wire-cutting jaws, the pliers are comfortable to handle.

WANT TO KNOW MORE?

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TEXACO’S YOUR MAN TEXACO

Texaco Delo 400 XSP SAE 5W-20 is a new premium performance synthetic heavy-duty engine oil that provides robust protection and optimum fuel economy in high performance, low emissions engines used in demanding onhighway applications. It meets the latest MAN M3977 standards for modern diesel engines with diesel particulate filters, and latest Euro VI-d emission requirements.

The oil is claimed to improve fuel economy while protecting components from wear and increasing engine service life. Its low viscosity, synthetic base oil technology helps cold startups and diesel engine performance in sub-zero temperatures. In addition, it is formulated to minimise wear, scuffing, and bore polishing, as well as aiding soot dispersion.

Developed specifically for use in MAN Euro VI-d commercial vehicles, it is recommended for use in the latest generation MAN trucks and buses that require MAN M3977 approved engine oils. This includes vehicle types E, F, J and K with D26 and D38 engines that are equipped with EFR and SCR+CRT, and D2676 and D3876 engines.

WANT TO KNOW MORE?

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APRIL’S TOPFIVE 1

Those of you not taking advantage of the CVW website are truly missing out. With an array of technical articles, breaking news and helpful business tips, it’s a great source of information right at your fingertips. This month, CVW’s Freya Coleman, takes a look at the most popular articles on the website from the past month.

1 PRODUCT SHOWCASE

Kicking off this month’s top online articles, CVW talks to ToolTruck, one of the largest independent mobile distributors of automotive hardware and tools in the UK, about what it can offer the busy workshop through its network of mobile dealers. This includes power tools, hand tools and toolboxes, holding a stock of more than 7000 product lines of major brands.

WWW.RDR.LINK/ VAY031

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3 5

4

2 INTRODUCING ZF'S ELECTRIFIED TRAILER

Claiming to be setting a new industry benchmark for efficiency, ZF has introduced its electric trailer. With its integrated drive system, the trailer effectively allows a conventional truck to become a hybrid.

WWW.RDR.LINK/ VAY032

3 NEW TO THE MARKET

Knorr-Bremse, a leading supplier to commercial and public service vehicles, is making a splash into the aftermarket with Fersa bearings. The range includes taper roller bearings, wheel bearing kits, compact bearing units and wheel bearing units.

WWW.RDR.LINK/ VAY033

WHEEL ALIGNMENT POINTERS

If you’ve ever wondered how often wheel alignment should be carried out on commercial vehicles, Russ Coad, managing director of AES UK, offers some pointers. He concludes by emphasising the importance of wheel alignment as an investment in the efficiencies of your fleet.

WWW.RDR.LINK/ VAY034

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REMANUFACTURING BENEFITS

Rounding off this month’s top online articles is Barney Milles, managing director of Ceramex, who explains the benefits of and the process behind the company’s HGV DPF remanufacturing. He argues that remanufacturing provides a more sustainable and faster turnaround solution to keeping vehicles efficient and environmentally compliant.

WWW.RDR.LINK/ VAY035

Here is a useful summary of all the adverts that appear in this issue of Commercial Vehicle Workshop. Each is listed with its page number and a direct URL that will get you straight to the relevant online information.

Borg Warner Aftermarket ............................................(page 28)

www.rdr.link/VAY100

Bosch Aftermarket ........................................................(page 4)

www.rdr.link/VAY101

Castrol ..............................................................(bound outsert)

www.rdr.link/VAY102

Castrol ....................................................................(back cover)

www.rdr.link/VAY103

CVW Online ................................................(Inside back cover)

www.rdr.link/VAY104

Eminox ........................................................................(page 33)

www.rdr.link/VAY105

Esprit ..........................................................................(page 37)

www.rdr.link/VAY106

Ferdinand Bilstein UK Ltd ............................................(page 9)

www.rdr.link/VAY107

Jack Sealey Ltd ..........................................................(page 16)

www.rdr.link/VAY108

Knorr-Bremse Truck Services ....................................(page 31)

www.rdr.link/VAY109

Liftmaster Ltd ..............................................................(page 41)

Mann+Hummel (UK) Ltd ............................................(page 27)

www.rdr.link/VAY115 Stertil UK Ltd ................................................(inside front cover) www.rdr.link/VAY116 T Cards Direct ............................................................(page 45)

www.rdr.link/VAY117

Totalkare Heavy Duty Work ........................................(page 19) www.rdr.link/VAY118

KEEP UPTO DATE WITH CVW

F o r a l l t h e l a t e s t i n d u s t r y n e w s , b u s i n e s s a d v i c e a n d t e c h n i c a l g u i d e s f ro m t h e t r a d e m a g a z i n e f o r C V s e r v i c i n g a n d re p a i r p ro f e s s i o n a l s