Prius recall pales next to faulty software in Mercedes Sensotronic brakes

By John Dodge | Feb 9, 2010 |

Yesterday’s recall of 133,000 2010 Toyota’s Pruis hybrids isn’t the first time ABS braking software has been a problem. In fact, Toyota’s recall of 133,000 Prius hybrids and 14,500 Lexus hybrids is tiny compared to the mother of all electronic brake recalls.

Mercedes recalled almost two million SL500s and E-Class vehicles in 2004-05 and ended up scrapping its brake-by-wire Sensotronic Brake Control system for its major models. Hailed as the future in 2001, Sensotronic brakes were developed at a pricetag of $173 million by Bosch and then DaimlerChrysler AG.

The culprit? Faulty software.

“The technology eliminates the mechanical link between the driver’s brake pedal and the brakes, substituting an electrical link that actuates the brake calipers. Customer complaints were linked to the failure of software for the brake system. When the system failed, the hydraulic system took over. But that resulted in a longer stopping distance and additional brake pedal effort by the driver,” according to an Autoweek story in December, 2005.

Mercedes returned to conventional hydraulic brakes in its major models even though Mercedes insiders maintained the Sensotronic was better. Customers simply lost faith in the Sensotronic brakes. Mercedes is still scrubbing away the tarnish on its reputation.

Of course, Toyota isn’t being hammered just for the relatively small Prius and Lexus hybrid recalls. Its problems all started with much, much larger sticking accelerator problem across most of its major models.

Larry Dignan in a post this morning asks how software updates and bug fixes can be downloaded to automobile systems. Indeed, today’s models after the driver are essentially controlled by computers. Arguing that computers and software should be excluded from cars is silly. After all, jetliners could not fly without myriad computers. We can’t turn back the clock or technology.

But for years now, we’ve seen the results of bad software in automobiles and there’s just going to be more of it as cars transition to electric powertrains. The Prius software problem could be just the tip of the iceberg.

Sensors, controllers, actuators and software comprise brake-by-wire systems. credit: Wikipedia

Sensors, controllers, actuators and software comprise brake by wire systems. credit: Wikipedia

As for updates and patches, your car could download them over a wireless link just like a laptop. Or, you could download patches from the Internet onto a memory stick embedded in your car key or fob. Start the car, and the patch is downloaded.

Perhaps, this is something manufacturers should have thought about when cars became so dependent on software. No fuss. No bother. Anything to keep me away from the dealer.

One other downside to rising automotive complexity: do-it-yourselfers have been removed from car repair and maintenance for all but oil changes and swapping out like air filters. There’s no more tinkering with a mechanical carburetor or bleeding the brakes yourself. Cars are too complex for that.

Advances in technology, environmental requirements and safety and performance improvements drive automotive engineering. But I also see complexity as a conspiracy to drive you back the dealer when anything goes wrong. Technology marches on.

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  •  
    1

    williamspurlock

    02/09/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    First, while I agree that it's a shame that we can no longer tinker with our cars, remember that the average car gets 2 to 3 times the mileage that it did back then. My primary problem with your idea is the community of nitwit hackers out there. I worry, and take all possible precautions when I plug my computer into the net, and if it crashes it's just annoying. The idea of plugging my car into the net and having some hacker take control of it is terrifying. If it crashes I might be dead, and I can't make a backup of me.

  •  
    2

    ejhonda

    02/10/10 | Report as spam

    It's only enjoyable to kick #1 in the shins

    Who wants to beat up on the also-rans? Who cares about issues impacting the rich & snooty? Toyota's problems get way more traction with the public because it involves the #1 automobile manufacturer, and it impacts Joe Six Pack.

    The problem with many of these innovations is they introduce more complexity, and thus more chance for failure, into systems. Which is more likely to fail: A mechanical dipstick to check your oil, or BMW's electronic oil level sensor? The electronic version is convenient, as long as it works. But I guarantee you the mechanical dipstick is far superior in reliability over the long haul.

    If we can't figure out how to properly secure email so it isn't 90% penis enlargement offers, then we sure as hell aren't going to be able to safely hook our vehicles to the 'net.

  •  
    3

    MichP

    02/10/10 | Report as spam

    I'm Sure They Thought About It

    Of course they want you to go to the dealer for fixes. Besides the liability if a hacker got into their patch system, they keep their dealers happy. Service = revenue.

  •  
    4

    lylelwr

    02/10/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    I disagree with the statement that we can't possibly make simple, reliable cars. Cars do not HAVE to have complex electronic systems just to run things like the throttle and brakes. If you want to add electronic wiz bang, do it to the stereo system and leave my brakes alone.

  •  
    5

    rgk@...

    02/10/10 | Report as spam

    Costly Window treatment

    I recall a side window dropping off the track, after buying my first car in the 60's. Pop off the door panel, reseat thew glass, reattach panel and put crank handle back on. Good to go at Zero $. About 2 years ago the passengers window dropped off track. (power windows, Pontiac Grand AM, glass not damaged.). Took it in and a day later, plus rental car, it cost well over $600. $128 per hour labor plus 2 different computer control units.
    Give me crank handles and wing windows any day.

    I won't talk to them about the clicking from the turn signals, because then they have to mess with the costly air bag.

    Where does it stop !

  •  
    6

    DadsPad

    02/10/10 | Report as spam

    the problem with software upgrades/patches

    is that they often are not, necessarily, tested properly. As we have all experienced, the latest and greatest software can change things not related with the problem the patch addresses. The patch may fix the brakes, but one headlight blinks constantly, or something else.

  •  
    7

    bigpicture

    02/10/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    These kinds of issues are caused by applying the "fly by wire" technology to applications
    that are HIGH RISK like brakes and accelerator functions. Do they not remember the AirBus fiasco where there were out of control 300 passenger jets doing barrel rolls. And otherwise
    simply taking control out of the pilots hands.

  •  
    8

    AlexKovnat

    02/11/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    I have thought for years, that the future of auto dealerships is to sell, not so much cars, as transportation services and solutions. I see nothing wrong with having to bring my car to my friendly local Toyota, Ford, Mercedes-Benz, etc., dealer every 90 days or so for software upgrades. What's the difference between that and other periodic checks and services?

  •  
    9

    wkc

    02/11/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    I worked with a guy who used the term "technolust" when talking about things like this. I think it's relevant here because many of the features do not add to the day to day experience of driving a car that much. What they do is to differentiate it in marketing terms.
    Driving a car should be a skill that is continuously honed by applying attention to the act of driving. A mechanical accelerator that jams can be lifted by the drivers foot or the car put into neutral. Saying this is too difficult and should all be taken care of by some computer system removes the onus from the driver to drive.
    Computers have their place in vehicles but they cannot and should not try to become a chauffeur.
    The more complex vehicles become the more they will have to go back to the dealers because they are more difficult to work on (ever tried to change the headlight bulb on a Merc A class!) and the tighter you are bound to the dealership.

  •  
    10

    ssco00

    02/11/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    Ah, those "good old days" when everything was simple and nothing went wrong. Oh, if we did all those things under the shade tree and could fix anything ourselves, it seems to follow that quite a bit did go wrong else where did we get the practice and experience? Everyone forgets that the US gumment mandates both both mileage and low emissions. One or the other would be relatively simple, but BOTH at the same time is not. And, the consumer wants a car to start easily in the worst of winter and wants it to warm up quickly and not stumble and stall for the first 15 minutes or so.
    The last ten years I worked before retiring and moving to a warm place I kind of reverse engineered vehicle electrical systems for GM light trucks and drew schematic diagrams of all for the service manuals. A complete set for the platform could be four volumes representing about 4000 pages. Schematics were needed to help service personnel diagnose electrical problems. These were so much in demand, they eventually published a separate complete collection of schematics for the platform. That would run 150 to 200 pages and didn't require a wheelbarrow to move it to a work station. It was pretty popular.
    How do door windows go off track? I have been driving more than 50 years and never has that happen. My Volvo has electronic everything, gives great performance with high mileage, has a large cargo space that I put to good use moving here, and the seats adjust to allow 800 mile driving days without discomfort or fatigue. I doubt that there was any car of the "good old days" that would do any of that. And, 50 years ago, there were far fewer cars on the road, people drove fewer miles per year at lower speeds than today but had numerically more fatalities than we do today thanks to the passenger protection engineered into the design of modern vehicles.

    Neither this performance or protection is an add on product, they must both be treated as systems, and engineered from the ground up, not done by gosh and by golly. They are not simple and cannot be. Care requires the efforts of knowledgeable technicians using proper diagnostic tools and, of course, good service manuals with accurate schematics.

  •  
    11

    alterego1701

    02/22/10 | Report as spam

    RE: Prius recall pales next to faulty software in Mercedes Sensotronic brakes

    I'm with the "keep it simple" shade tree mechanic crowd. I'd pay more than a new Mercedes cost if I could buy a car that was as mechanical, and as repairable, as the ones from the 1950s-1980s. I'm still driving a pair of 1980s diesel Mercedes vehicles and intend to keep them until rust takes them from me. There's nothing new I'd even want to buy. They've both got over 350,000 miles on them. And when something does go wrong occasionally, it's a hardware part. I can identify it, put a wrench on it, take it off, and put a new one on. Or, more often than not, take it apart and *repair* it, not just replace it.

    These silly computerized things... it's too expensive, all other things aside. Not everybody can afford to rush to the dealership for a dealer-only $1000 computer that may or may not fix the problem, when they could fix a simpler car at home in their garage for free except for the reasonable parts.

    This new stuff is fine for the first two or three years. But then what? My Mercedes fleet is a 1982 and a 1986. Where will *these* new cars be when they are 24 and 28 years old? I'll be shocked if even one is running. And there certainly won't be "software updates at the dealership" for them.

    Cars, like every other appliance, should still be built with the capacity to make repairs and keep running them infinitely, unless there's body damage or something other than "just becoming obsolete." Some of us aren't spending every dime we own constantly making car payments, paying for depreciation and interest, and some of us would happily spend more money than new cars are selling for today to get one that was built to last ten years, and then be rebuilt and last another ten.

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John Dodge

John Dodge has answered the call of journalism for 33 years, most of the time covering technology, engineering and business. While he's run magazines, newsweeklies and web sites, reporting and writing always took up half his time. He has have plied his craft at the WSJ, Boston Globe, PC Week (now eWeek), EDN, Design News, Electronic Business, Bio-IT World, Health-IT World, the Lowell Sun, Haverhill Gazette and Newburyport Daily News. He would have like to have been around when Boston supported seven or more newspapers (1940s) and while steam locomotives still pulled trains, but that era was nearly over by the time he raced into the world. That said, he has been blogging and shooting and editing video, writing for web and other online contents tasks for years now.

He has won numerous journalism awards in the past two years, including two Eddie Golds, one Neal finalist and the IEEE Award for Distinguished Journalism all for his reporting and coverage of the Boeing 787 Dreamliner.

Besides his family and myriad hobbies, reporting and writing is why he gets up in the morning. His personal blog focuses on netbooks and is called The Dodge Retort.

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The Thinking Tech blog focuses on technologies such as virtualization, smart electric grids, enterprise 2.0, open source, data center management, green technology and the intersection between the innovation and application of these advancements.