Relebogile Mabotja speaks to Nicol Louw a Technical Expert unpacking how software engineers calibrate modern car engines to run efficiently, reliably, and in a way that reduces costly warranty claims.
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Transcript
Episode Transcript
Available transcripts are automatically generated. Complete accuracy is not guaranteed.
Speaker 1 (00:00):
Seven o two the Car Feature at eighteen minutes to
three o'clock time for our car feature get in touch
with us Oh double one double a three h seven
oh two and the whatzap line oh seven two seven
oh two one seven oh two. We are joined by
Nickel Low, our technical car expert. Not only can you
start to get your questions in early for your vehicles
(00:22):
and your technical car issues, but we also will be
chatting about how software engineers calibrate car engines to reduce
warranty costs.
Speaker 2 (00:32):
So your questions and comments.
Speaker 1 (00:33):
OH double one double a three oh seven oh two
and the whatsap line oh seven two seven oh two
one seven oh two Nickel, Happy Tuesday.
Speaker 3 (00:41):
How are you, hiribhile? All good, All good, Thank you, Thank.
Speaker 2 (00:46):
You so so much.
Speaker 1 (00:47):
I'm excited for this one because I'm always curious about
the calibrating of car engines and how that works.
Speaker 3 (00:56):
So in my previous life I was actually a calibration engineer.
I worked for Ford in the UK for almost five years.
So the two stories I'm going to tell it's quite
interesting because your warranty cost is a big thing for
the OEMs and if there's cost obviously during a warranty period.
It hurts the bottom line tremendously. But how would the
(01:19):
OEM prove that the driver or the owner of the
vehicle didn't mess up and now they had to pay
for it. So I'll give you two examples they're getting clever.
The one example is starter motor abuse. So we had
a situation on it got actually four transit back in
the day where the brand new vehicles will end up
(01:40):
with a burnout starter, and they couldn't explain this even
at a dealer four courts. They were replacing starters left,
right and center and couldn't understand why they have such
a massive warranty cost on starter motors. And then what
eventually panned out was when these vehicles leave factory, they've
got minimum level of fuel in them, obviously to say,
of course, so a couple of liters in there, and
(02:02):
these vehicles get started and driven maybe to the ship
and gets driven to the truck and to the fore
court and maybe moved around. And at some point if
you put in two little fuel in a factory or
in a plant where they built a run out of diesel,
and they found out, okay, if it's a manual vehicle,
in your in first gear and your clutch is out,
and you can actually drive it on the starter motor.
(02:22):
You don't have to fuel it. So they continued cranking
it and driving it on the starter motor. I even
up transported trucks and all of that, and that's how
they managed to burn out the starter because it was
never intended to move the vehicle on the starter motor.
So as a software engineer, what we did was we
only allowed you a certain time to crank the engine.
(02:42):
So for example, you'll get maybe ten seconds, so you're
trying to start the engine, it starts cranking, you get
ten seconds, and then it will shut off the cranking
and it will give you that for three times. You
get three times of ten seconds, and then it disables
the all starting event for half an hour. Because if
it didn't start for ten seconds cranking three times in
(03:04):
a row, then there's definitely something wrong that that cranking
wouldn't help. And that sort of reduced the warrant it
costing cost. Immediately, the starter motor warrant it cost disappeared
because people realize, oh, shots, we can't drive it on
the starter motor anymore. Because you've got limited time of
doing this and then be stuck anyway, So let's try
to just fuel the vehicle and drive it as it's
opposed to. So that was the one event. The other
(03:27):
one where engine warranty cost when the old engine just
got massive mechanical damage.
Speaker 4 (03:36):
And what actually happened.
Speaker 3 (03:38):
Is on a commercial vehicle like the Sons that they
used to be all manual. Now today a lot of
these vehicles are automatic. But in the days with a manual,
first of all, you've got a ref limiter to limit
the maximum amount of refs that you can get out
of a motor. So even if you put your foot
flat you don't shift gear, you will bounce off the
(03:58):
reef limited at the red line and it shouldn't cause
damage to the engine.
Speaker 4 (04:02):
But what will cause a damage to the engine is.
Speaker 3 (04:05):
If you accelerate. So you accelerate hard in third gear
up to the red line and you're trying to look
fourth gear, but you actually go for a second. Then
you overreff the engine to the point where you just
self destruct. And the problem was that you get this
warranty cost of the engine is gone. You've got no
evidence to point to the abuse of the driver of
(04:28):
a misshift. So what we did as calibration engineers. We
obviously know where the redline of the engine is, so
it's a diesel engine is around four and a half
or five thousand rpm max. You'll put a fault code
in there that will set if that engine revolutions go
above say six thousand rpm, because there's no way that
(04:49):
you can get to that point without the misshift. So
what happened is, Okay, the guy will all contact the MSA,
I've got a blowing engine, and we will just plug
in the two. They will read it and say there's
a fault code. Yeah, it's set because your engine rpm
when a thousand rpm above the redline.
Speaker 4 (05:08):
Only way you could do it is a misshift.
Speaker 3 (05:10):
So the warranty cost it gets denied and the owner
or the client then has to pay for the engine replacement.
So you can imagine what warranty cost was saved just
with that little software two week and a fault code
that would set for something like this.
Speaker 2 (05:25):
So what would you recommend that listeners do with that?
Speaker 3 (05:30):
Well, first thing, if you drive a manual, don't mishift
your card.
Speaker 4 (05:33):
That's a big no no.
Speaker 3 (05:37):
So be careful when especially when you're driving at high
engine RPMs and you're going for the next gear. Don't
go with gear gear down, go with the gear up,
Otherwise there will be big problems. That's solved with automatic transmissions.
With automatic transmission, you can't actually do a misshift. So
if you're driving an autocod, then you're fine, and then.
Speaker 4 (05:57):
Start the motor. Abuse.
Speaker 3 (05:59):
It doesn't help. Just cranking and cranking and cranking the engine.
If it's not firing, then it's either out of fuel
or there's something else that's desperately wrong. So the starter
motor is designed for a certain amount of cranking and
it is up and eventually it will burn out.
Speaker 4 (06:14):
So yeah, I'll just be sensitive. All right.
Speaker 2 (06:17):
We're going to take a break, Nickel.
Speaker 1 (06:19):
When we come back, we're going to take all of
the technical car questions and any questions also around this
software where engineers that are using this calibration in engine
control units of vehicles OU double one, double A three
H seven oh two in the WhatsApp line oh seven
two seven oh two one seven O two seven O
(06:40):
two the car feature at eighteen minutes to three o'clock
time for our car feature. Get in touch with us
at double one, double A three or seven oh two
and the WhatsApp line oh seven two seven oh two
one seven oh two. We are joined by nickel Low,
our technical car expert. Not only can you start to
get your questions in early for your vehicles and your
(07:01):
technical car issues, but we also will be chatting about
how software engineers calibrate car engines to reduce warranty costs.
So your questions and comments oh double one double a
three seven oh two and the WhatsApp line oh seven
two seven two one seven oh two.
Speaker 2 (07:19):
Nicol Happy Tuesday.
Speaker 3 (07:20):
How are you, Hi, Riber Hiley? All good, all good,
thank you, Thank.
Speaker 2 (07:24):
You so so much.
Speaker 1 (07:25):
I'm excited for this one because I'm always curious about
the calibrating of car engines and how that works.
Speaker 3 (07:35):
So in my previous life I was actually a calibration engineer,
Hi Will. I work for Ford in the UK for
almost five years. So the two stories I'm going to
tell is quite interesting because your warranty cost is a
big thing for the OEMs, and if there is cost,
obviously during a warranty period, it hurts the bottom line tremendously.
(07:57):
But how would the OEM prove that the driver or
the owner of the vehicle didn't mess up and now
they had to pay for it. I'll give you two
examples they're getting clever. The one example is starter motor abuse.
So we had a situation on it got actually four
transit back in the day where the brand new vehicles
(08:18):
will end up with a burnout starter, and they couldn't
explain this even at a dealer four courts. They were
replacing starters left, right and center and couldn't understand why
do they have such a massive warranty cost.
Speaker 4 (08:30):
On starter motors.
Speaker 3 (08:31):
And then what eventually panned out was when these vehicles
leave factory, they've got minimum level of fuel in them,
obviously to save costs. So a couple of liters in there,
and these vehicles get started and driven maybe to the ship,
and gets driven to the truck and to the fore
court and maybe moved around. And at some point if
you put in two little fuel in a factory or
(08:51):
in a plant where they built a run out of diesel,
and they found out, okay, if it's a manual vehicle
in your first gear and your clutch is out and
you can actually drive it on the starter motor, you
don't have to fuel it. So they continued cranking it
and driving it on the starter motor if even up
transported trucks and all of that, and that's how they
managed to burn out the starter because it was never
(09:12):
intended to move the vehicle on.
Speaker 4 (09:14):
The starter motor.
Speaker 3 (09:15):
So as a software engineer, what we did was we
only allowed you a certain time to crank the engine.
So for example, you'll get maybe ten seconds, so you're
trying to start the engine, it starts cranking, you get
ten seconds, and then it will shut off the cranking,
and it will give you that.
Speaker 4 (09:32):
For three times. You get three times.
Speaker 3 (09:34):
Of ten seconds, and then it disables the all starting
event for half an hour. Because if it didn't start
for ten seconds cranking three times in a row, then
there's definitely something wrong that cranking wouldn't help. And that
sort of reduced the whyran't it costing cost? Immediately the
starter motor warrant it cost disappeared because people realized, oh shots,
we can't drive it on the starter motor anymore because
(09:56):
you've got limited time of doing this, and then we're
stuck anyway, So they try to just fuel the vehicle
and drive it as it's supposed too. So that was
the one event. The other one where engine warranty cost
when the old engine just got massive mechanical damage. And
what actually happened is on a commercial vehicle like the Tones,
(10:19):
that they used to be all manual. Now today a
lot of these vehicles are automatic. But in the days
with a manual, first of all, you've got a ref
limiter to limit the maximum amount of refs that you
can get out of a motor. So even if you
put your foot flat you don't shift gear, you will
bounce off the ref limited at the red line and
it shouldn't cause damage.
Speaker 4 (10:40):
To the engine.
Speaker 3 (10:41):
But what will cause damage to the engine is if
you accelerate. So you accelerate hard in third gear up
to the red line and you're trying to look fourth gear,
but you actually go for a second. Then you over
reff the engine to the point where you just self destruct.
And the problem was that you get this warranty cost
of the engine is gone. You've got no evidence to
(11:04):
point to the abuse of the driver of a misshift.
So what we did as calibration engineers, we obviously know
where the readline of the engineers so it's a diesel engine,
is around four and a half or five thousand rpm.
Speaker 4 (11:18):
Max.
Speaker 3 (11:18):
You'll put a fault code in there that will set
if that engine revolutions go above say six thousand rpm,
because there's no way that you can get to that
point without a misshift. So what happened is, Okay, the
guy will all contact the MSA, I've got a blowing engine,
and we will just plug in their tool.
Speaker 4 (11:39):
They will read it and.
Speaker 3 (11:40):
Say there's a fault code. Yeah, it's set because your
engine rpm when a thousand rpm above the redline.
Speaker 4 (11:47):
Only way you could do it is a misshift.
Speaker 3 (11:49):
So the warranty cost it gets denied and the owner
or the client then has to pay for the engine replacement.
So you can imagine what warranty cost was saved just
for that little software two week and a fold code
that would set for something like this.
Speaker 2 (12:04):
So what would you recommend that listeners do.
Speaker 3 (12:07):
With that, Well, first thing, if you drive a manual,
don't misshift your God, that's a big no no. So
be careful when especially when you're driving at high engine
RPMs and you're going for the next gear don't go
with gear gear down, go with gear up, otherwise there
will be big problems. That's solved with automatic transmissions. With
(12:29):
automatic transmission, you can't actually do a misshift. So if
you're driving an autocod then you're fine. And then starter
motor abuse. It doesn't help. Just cranking and cranking and
cranking the engine. If it's not firing, then it's it's
either out of fuel or there's something else that's desperately wrong.
Speaker 4 (12:46):
So the starter.
Speaker 3 (12:47):
Motor is designed for a certain amount of cranking and
it is up and eventually it will burn out.
Speaker 4 (12:53):
So yeah, just be sensitive.
Speaker 2 (12:56):
All Right, we're gonna take a break, Nicole.
Speaker 1 (12:58):
When we come back, we're going to you take all
of the technical card questions and any questions also around
this software ware engineers that are using this calibration in
engine control units of vehicles oh double one double A
three oh seven oh two in the WhatsApp line O
seven two seven oh two one seven O two
Seven o two the Car Feature at eighteen minutes to
three o'clock time for our car feature get in touch
with us Oh double one double a three h seven
oh two and the whatzap line oh seven two seven
oh two one seven oh two. We are joined by
Nickel Low, our technical car expert. Not only can you
start to get your questions in early for your vehicles
(00:22):
and your technical car issues, but we also will be
chatting about how software engineers calibrate car engines to reduce
warranty costs.
Speaker 2 (00:32):
So your questions and comments.
Speaker 1 (00:33):
OH double one double a three oh seven oh two
and the whatsap line oh seven two seven oh two
one seven oh two Nickel, Happy Tuesday.
Speaker 3 (00:41):
How are you, hiribhile? All good, All good, Thank you, Thank.
Speaker 2 (00:46):
You so so much.
Speaker 1 (00:47):
I'm excited for this one because I'm always curious about
the calibrating of car engines and how that works.
Speaker 3 (00:56):
So in my previous life I was actually a calibration engineer.
I worked for Ford in the UK for almost five years.
So the two stories I'm going to tell it's quite
interesting because your warranty cost is a big thing for
the OEMs and if there's cost obviously during a warranty period.
It hurts the bottom line tremendously. But how would the
(01:19):
OEM prove that the driver or the owner of the
vehicle didn't mess up and now they had to pay
for it. So I'll give you two examples they're getting clever.
The one example is starter motor abuse. So we had
a situation on it got actually four transit back in
the day where the brand new vehicles will end up
(01:40):
with a burnout starter, and they couldn't explain this even
at a dealer four courts. They were replacing starters left,
right and center and couldn't understand why they have such
a massive warranty cost on starter motors. And then what
eventually panned out was when these vehicles leave factory, they've
got minimum level of fuel in them, obviously to say,
of course, so a couple of liters in there, and
(02:02):
these vehicles get started and driven maybe to the ship
and gets driven to the truck and to the fore
court and maybe moved around. And at some point if
you put in two little fuel in a factory or
in a plant where they built a run out of diesel,
and they found out, okay, if it's a manual vehicle,
in your in first gear and your clutch is out,
and you can actually drive it on the starter motor.
(02:22):
You don't have to fuel it. So they continued cranking
it and driving it on the starter motor. I even
up transported trucks and all of that, and that's how
they managed to burn out the starter because it was
never intended to move the vehicle on the starter motor.
So as a software engineer, what we did was we
only allowed you a certain time to crank the engine.
(02:42):
So for example, you'll get maybe ten seconds, so you're
trying to start the engine, it starts cranking, you get
ten seconds, and then it will shut off the cranking
and it will give you that for three times. You
get three times of ten seconds, and then it disables
the all starting event for half an hour. Because if
it didn't start for ten seconds cranking three times in
(03:04):
a row, then there's definitely something wrong that that cranking
wouldn't help. And that sort of reduced the warrant it
costing cost. Immediately, the starter motor warrant it cost disappeared
because people realize, oh, shots, we can't drive it on
the starter motor anymore. Because you've got limited time of
doing this and then be stuck anyway, So let's try
to just fuel the vehicle and drive it as it's
opposed to. So that was the one event. The other
(03:27):
one where engine warranty cost when the old engine just
got massive mechanical damage.
Speaker 4 (03:36):
And what actually happened.
Speaker 3 (03:38):
Is on a commercial vehicle like the Sons that they
used to be all manual. Now today a lot of
these vehicles are automatic. But in the days with a manual,
first of all, you've got a ref limiter to limit
the maximum amount of refs that you can get out
of a motor. So even if you put your foot
flat you don't shift gear, you will bounce off the
(03:58):
reef limited at the red line and it shouldn't cause
damage to the engine.
Speaker 4 (04:02):
But what will cause a damage to the engine is.
Speaker 3 (04:05):
If you accelerate. So you accelerate hard in third gear
up to the red line and you're trying to look
fourth gear, but you actually go for a second. Then
you overreff the engine to the point where you just
self destruct. And the problem was that you get this
warranty cost of the engine is gone. You've got no
evidence to point to the abuse of the driver of
(04:28):
a misshift. So what we did as calibration engineers. We
obviously know where the redline of the engine is, so
it's a diesel engine is around four and a half
or five thousand rpm max. You'll put a fault code
in there that will set if that engine revolutions go
above say six thousand rpm, because there's no way that
(04:49):
you can get to that point without the misshift. So
what happened is, Okay, the guy will all contact the MSA,
I've got a blowing engine, and we will just plug
in the two. They will read it and say there's
a fault code. Yeah, it's set because your engine rpm
when a thousand rpm above the redline.
Speaker 4 (05:08):
Only way you could do it is a misshift.
Speaker 3 (05:10):
So the warranty cost it gets denied and the owner
or the client then has to pay for the engine replacement.
So you can imagine what warranty cost was saved just
with that little software two week and a fault code
that would set for something like this.
Speaker 2 (05:25):
So what would you recommend that listeners do with that?
Speaker 3 (05:30):
Well, first thing, if you drive a manual, don't mishift
your card.
Speaker 4 (05:33):
That's a big no no.
Speaker 3 (05:37):
So be careful when especially when you're driving at high
engine RPMs and you're going for the next gear. Don't
go with gear gear down, go with the gear up,
Otherwise there will be big problems. That's solved with automatic transmissions.
With automatic transmission, you can't actually do a misshift. So
if you're driving an autocod, then you're fine, and then.
Speaker 4 (05:57):
Start the motor. Abuse.
Speaker 3 (05:59):
It doesn't help. Just cranking and cranking and cranking the engine.
If it's not firing, then it's either out of fuel
or there's something else that's desperately wrong. So the starter
motor is designed for a certain amount of cranking and
it is up and eventually it will burn out.
Speaker 4 (06:14):
So yeah, I'll just be sensitive. All right.
Speaker 2 (06:17):
We're going to take a break, Nickel.
Speaker 1 (06:19):
When we come back, we're going to take all of
the technical car questions and any questions also around this
software where engineers that are using this calibration in engine
control units of vehicles OU double one, double A three
H seven oh two in the WhatsApp line oh seven
two seven oh two one seven O two seven O
(06:40):
two the car feature at eighteen minutes to three o'clock
time for our car feature. Get in touch with us
at double one, double A three or seven oh two
and the WhatsApp line oh seven two seven oh two
one seven oh two. We are joined by nickel Low,
our technical car expert. Not only can you start to
get your questions in early for your vehicles and your
(07:01):
technical car issues, but we also will be chatting about
how software engineers calibrate car engines to reduce warranty costs.
So your questions and comments oh double one double a
three seven oh two and the WhatsApp line oh seven
two seven two one seven oh two.
Speaker 2 (07:19):
Nicol Happy Tuesday.
Speaker 3 (07:20):
How are you, Hi, Riber Hiley? All good, all good,
thank you, Thank.
Speaker 2 (07:24):
You so so much.
Speaker 1 (07:25):
I'm excited for this one because I'm always curious about
the calibrating of car engines and how that works.
Speaker 3 (07:35):
So in my previous life I was actually a calibration engineer,
Hi Will. I work for Ford in the UK for
almost five years. So the two stories I'm going to
tell is quite interesting because your warranty cost is a
big thing for the OEMs, and if there is cost,
obviously during a warranty period, it hurts the bottom line tremendously.
(07:57):
But how would the OEM prove that the driver or
the owner of the vehicle didn't mess up and now
they had to pay for it. I'll give you two
examples they're getting clever. The one example is starter motor abuse.
So we had a situation on it got actually four
transit back in the day where the brand new vehicles
(08:18):
will end up with a burnout starter, and they couldn't
explain this even at a dealer four courts. They were
replacing starters left, right and center and couldn't understand why
do they have such a massive warranty cost.
Speaker 4 (08:30):
On starter motors.
Speaker 3 (08:31):
And then what eventually panned out was when these vehicles
leave factory, they've got minimum level of fuel in them,
obviously to save costs. So a couple of liters in there,
and these vehicles get started and driven maybe to the ship,
and gets driven to the truck and to the fore
court and maybe moved around. And at some point if
you put in two little fuel in a factory or
(08:51):
in a plant where they built a run out of diesel,
and they found out, okay, if it's a manual vehicle
in your first gear and your clutch is out and
you can actually drive it on the starter motor, you
don't have to fuel it. So they continued cranking it
and driving it on the starter motor if even up
transported trucks and all of that, and that's how they
managed to burn out the starter because it was never
(09:12):
intended to move the vehicle on.
Speaker 4 (09:14):
The starter motor.
Speaker 3 (09:15):
So as a software engineer, what we did was we
only allowed you a certain time to crank the engine.
So for example, you'll get maybe ten seconds, so you're
trying to start the engine, it starts cranking, you get
ten seconds, and then it will shut off the cranking,
and it will give you that.
Speaker 4 (09:32):
For three times. You get three times.
Speaker 3 (09:34):
Of ten seconds, and then it disables the all starting
event for half an hour. Because if it didn't start
for ten seconds cranking three times in a row, then
there's definitely something wrong that cranking wouldn't help. And that
sort of reduced the whyran't it costing cost? Immediately the
starter motor warrant it cost disappeared because people realized, oh shots,
we can't drive it on the starter motor anymore because
(09:56):
you've got limited time of doing this, and then we're
stuck anyway, So they try to just fuel the vehicle
and drive it as it's supposed too. So that was
the one event. The other one where engine warranty cost
when the old engine just got massive mechanical damage. And
what actually happened is on a commercial vehicle like the Tones,
(10:19):
that they used to be all manual. Now today a
lot of these vehicles are automatic. But in the days
with a manual, first of all, you've got a ref
limiter to limit the maximum amount of refs that you
can get out of a motor. So even if you
put your foot flat you don't shift gear, you will
bounce off the ref limited at the red line and
it shouldn't cause damage.
Speaker 4 (10:40):
To the engine.
Speaker 3 (10:41):
But what will cause damage to the engine is if
you accelerate. So you accelerate hard in third gear up
to the red line and you're trying to look fourth gear,
but you actually go for a second. Then you over
reff the engine to the point where you just self destruct.
And the problem was that you get this warranty cost
of the engine is gone. You've got no evidence to
(11:04):
point to the abuse of the driver of a misshift.
So what we did as calibration engineers, we obviously know
where the readline of the engineers so it's a diesel engine,
is around four and a half or five thousand rpm.
Speaker 4 (11:18):
Max.
Speaker 3 (11:18):
You'll put a fault code in there that will set
if that engine revolutions go above say six thousand rpm,
because there's no way that you can get to that
point without a misshift. So what happened is, Okay, the
guy will all contact the MSA, I've got a blowing engine,
and we will just plug in their tool.
Speaker 4 (11:39):
They will read it and.
Speaker 3 (11:40):
Say there's a fault code. Yeah, it's set because your
engine rpm when a thousand rpm above the redline.
Speaker 4 (11:47):
Only way you could do it is a misshift.
Speaker 3 (11:49):
So the warranty cost it gets denied and the owner
or the client then has to pay for the engine replacement.
So you can imagine what warranty cost was saved just
for that little software two week and a fold code
that would set for something like this.
Speaker 2 (12:04):
So what would you recommend that listeners do.
Speaker 3 (12:07):
With that, Well, first thing, if you drive a manual,
don't misshift your God, that's a big no no. So
be careful when especially when you're driving at high engine
RPMs and you're going for the next gear don't go
with gear gear down, go with gear up, otherwise there
will be big problems. That's solved with automatic transmissions. With
(12:29):
automatic transmission, you can't actually do a misshift. So if
you're driving an autocod then you're fine. And then starter
motor abuse. It doesn't help. Just cranking and cranking and
cranking the engine. If it's not firing, then it's it's
either out of fuel or there's something else that's desperately wrong.
Speaker 4 (12:46):
So the starter.
Speaker 3 (12:47):
Motor is designed for a certain amount of cranking and
it is up and eventually it will burn out.
Speaker 4 (12:53):
So yeah, just be sensitive.
Speaker 2 (12:56):
All Right, we're gonna take a break, Nicole.
Speaker 1 (12:58):
When we come back, we're going to you take all
of the technical card questions and any questions also around
this software ware engineers that are using this calibration in
engine control units of vehicles oh double one double A
three oh seven oh two in the WhatsApp line O
seven two seven oh two one seven O two
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