When Tail Lights Lose Touch With Reality

To study the history of the automobile is to also be a student of technological progress — as with each decade’s models come new innovations to make them better handling, more corrosion-resistant, faster, more efficient, or whatever the needs of the moment dictate. But sometimes that technological advancement goes awry and works against the motorist, making for a vehicle that’s substantially worse than what went before. [FordTechMakuloco] has a video with an example in a Ford pickup, which we believe deserves to be shared.

The problem with the vehicle was simple enough, indeed it’s one we’ve had in the past ourselves. Water got into a tail light, and corroded some connectors. The difference with this Ford though was that such a simple fault took out the whole car, and that the fix for a simple tail light cost $5600. The first was due to a vehicle-wide CAN bus going down due to the electrical short, and the second was due to the assembly containing an assortment of wiring and modules which couldn’t be replaced separately. These included some form of side-facing parking radar, a component unnecessary for operation of the light itself. Some relatively straightforward design and component supply decisions such as separating subsystems across multiple CAN busses, ensuring individual modules are separately available, and even designing connectors to face downwards and self-drain, could have fixed it, but the automaker chose instead to build in some planned obsolescence. Would you buy a Ford truck after seeing the video below the break?

We’ve written here before about how automotive design has taken this wrong path, and even advanced a manifesto as to how they might escape it. This Ford tail light seems to us an egregious example of electronics-as-the-new-rust rendering what should be a good vehicle into a badly designed piece of junk, and honestly it saddens us to see it. Oddly, there was once a time when a Ford truck was about as good as you could get.

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3D Print Your Best Friend A Wheelchair

We all know that 3D printing has been a boon for people with different life challenges. But the Ford Motor Company in Mexico wants to help dogs that need mobility assistance. They’ve designed and released P-Raptor (we presume the P is for perro), a wheelchair for pooches with rear leg issues. The web page is in Spanish, and translating it didn’t seem to work for some reason, but if you have any Spanish, you can probably work it out or cut and paste just the text into your favorite translator.

The design is modular to adapt to different size dogs and different problems. It contains an electric motor in the tires. The tires themselves are oversized to help your friend cover rugged terrain. Dogs want to look cool, too, so a grill with lighting is included.

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Hackaday Links: July 16, 2023

Last week, we noted an attempt to fix a hardware problem with software, which backfired pretty dramatically for Ford when they tried to counter the tendency for driveshafts to fall out of certain of their cars by automatically applying the electric parking brake.

This week, the story is a little different, but still illustrates how software and hardware can interact unpredictably, especially in the automotive space. The story centers on a 2015 Optima recall for a software update for the knock sensor detection system. We can’t find the specifics, but if this recall on a similar Kia model in the same model year range and a class-action lawsuit are any indication, the update looks like it would have made the KSDS more sensitive to worn connecting rod damage, and forced the car into “limp home mode” to limit damage to the engine if knocking is detected.

A clever solution to a mechanical problem? Perhaps, but because the Kia owner in the story claims not to have received the snail-mail recall notice, she got no warning when her bearings started wearing out. Result: a $6,000 bill for a new engine, which she was forced to cover out of pocket. Granted, this software fix isn’t quite as egregious as Ford’s workaround for weak driveshaft mounting bolts, and there may very well have been a lack of maintenance by the car’s owner. But if you’re a Kia mechanical engineer, wouldn’t your first instinct have been to fix the problem causing the rod bearings to wear out, rather than papering over the problem with software?

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Hackaday Links: July 9, 2023

Good news this week from Mars, where Ingenuity finally managed to check in with its controllers after a long silence. The plucky helicopter went silent just after nailing the landing on its 52nd flight back on April 26, and hasn’t been heard from since. Mission planners speculated that Ingenuity, which needs to link to the Perseverance rover to transmit its data, landed in a place where terrain features were blocking line-of-sight between the two. So they weren’t overly concerned about the blackout, but still, one likes to keep in touch with such an irreplaceable asset. The silence was broken last week when Perseverance finally made it to higher ground, allowing the helicopter to link up and dump the data from the last flight. The goal going forward is to keep Ingenuity moving ahead of the rover, acting as a scout for interesting places to explore, which makes it possible that we’ll see more comms blackouts. Ingenuity may be more than ten-fold over the number of flights that were planned, but that doesn’t mean it’s ready for retirement quite yet.

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a modern car dipped into a chemical bath for electrodeposition adding a phosphate layer

Watching Paint Dry For Over 100 Years

A Model T Ford customer could famously get their car “in any color he wants, so long as it’s black.” Thus begins [edconway]’s recounting of the incremental improvements in car paint and its surprising role in mass production, marketing, and longevity of automobiles.

In it, we learn that the aforementioned black paint from Ford had so much asphalt in it that black was the only color that would work. Not to go down a This Is Spinal Tap rabbit hole, but there were several kinds of black on those Model Ts. Over 30 of them were used for various purposes. The paints also dried in different ways. While the assembly only took 12 hours, the paint drying time took days, even weeks backing up production and begging for innovation. [edconway] then fast-forwards to an era of “conspicuous consumption and ‘planned obsolescence’” with DuPont’s invention of Duco that brought color to the world of automobiles.

edconway graph of paint drying time by year

See the article for the real story of advances in paint technology and drying time. Paint application technology has also steadily improved over the years, so we recommend diving in to get the century’s long story.

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Hackaday Links: May 28, 2023

The Great Automotive AM Radio War of 2023 rages on, with the news this week that Ford has capitulated, at least for now. You’ll recall that the opening salvo came when the US automaker declared that AM radio was unusable in their EV offerings thanks to interference generated by the motor controller. Rather than fixing the root problem, Ford decided to delete the AM option from their EV infotainment systems, while letting their rolling EMI generators just keep blasting out interference for everyone to enjoy. Lawmakers began rattling their sabers in response, threatening legislation to include AM radio in every vehicle as a matter of public safety. Ford saw the writing on the wall and reversed course, saying that AM is back for at least the 2024 model year, and that vehicles already delivered without it will get a fix via software update.

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Hackaday Links: March 19, 2023

We get results! Well, sort of. You may recall that in this space last week we discussed Ford’s plans to exclude AM reception on the infotainment systems of certain of their cars starting in 2024. We decried the decision, not for the loss of the sweet, sweet content that AM stations tend to carry — although we always enjoyed “Traffic on the 8s” back in our dismal days of daily commuting — but rather as a safety concern, because AM radio can reach almost the entire US population with emergency information using just 75 stations. To our way of thinking, this makes AM radio critical infrastructure, and eliminating it from motor vehicles is likely to have unintended consequences. Now it seems like there’s some agreement with that position, as former administrators of FEMA (Federal Emergency Management Administration; and no, not FEDRA) have gotten together to warn about the dangers of deleting AM from cars. Manufacturers seem to be leaning into the excuse that EVs emit a lot of radio frequency interference, rendering static-sensitive AM receivers less useful than other, more profitable less susceptible modes, like digital satellite radio. That seems like a red herring to us, but then again, the most advanced infotainment option in any car we’ve ever owned is a CD player, so it’s hard for us to judge.

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