AEB System Installation Checklist: Ensure Safe Braking on All Fleets
Automatic Emergency Braking (AEB) systems represent one of the most significant safety advancements in modern vehicle technology, capable of reducing rear-end crashes by up to 50% according to NHTSA data. Whether retrofitting existing fleet vehicles or ensuring proper installation on new acquisitions, a methodical approach to AEB system implementation is critical for optimal performance and regulatory compliance. This comprehensive checklist guides fleet managers, safety directors, and technicians through the essential steps of AEB system installation, ensuring that all components are properly integrated, calibrated, and tested to deliver reliable collision avoidance functionality across your entire fleet.
AEB System Installation Checklist
1. Pre-Installation Assessment
- Verify vehicle compatibility with the specific AEB system model
- Confirm vehicle's electrical system can support AEB power requirements
- Check for any existing collision avoidance systems that may interfere
- Document vehicle's pre-installation brake performance as baseline
- Verify OEM approval for AEB retrofit (if applicable)
- Ensure technicians have completed required AEB installation training
- Confirm availability of all necessary installation tools and equipment
- Review warranty implications of AEB installation
- Photograph vehicle before installation for documentation
- Backup vehicle's ECU data before making any modifications
2. Component Installation
- Mount radar sensor(s) according to manufacturer specifications
- Install camera systems at specified locations (typically windshield)
- Mount control module in protected location with proper orientation
- Install driver display/interface in accessible dashboard location
- Connect system to vehicle's CAN bus following specified protocols
- Integrate with vehicle's braking system per installation guide
- Install any required supplementary hydraulic units
- Route all wiring with proper protection from heat and abrasion
- Secure all wiring with appropriate clips and fasteners
- Install system fuses in designated locations
- Apply all system warning labels in specified locations
- Mount ultrasonic sensors (if part of system) at proper bumper locations
3. Electrical and Systems Integration
- Verify proper voltage at all system connection points
- Confirm clean power and ground connections
- Check for proper CAN bus communication with vehicle systems
- Verify integration with brake controller
- Confirm AEB system receives vehicle speed data correctly
- Check steering angle sensor connectivity (if utilized)
- Verify throttle position sensor integration (if required)
- Confirm proper communication with any existing ADAS features
- Check for electrical interference between systems
- Verify system powers up and initializes correctly
- Confirm system enters standby mode appropriately
- Check that system activates at proper vehicle speed thresholds
4. Sensor Calibration and Alignment
- Perform radar sensor alignment using manufacturer's procedure
- Calibrate forward-facing camera using specified targets and distances
- Set proper detection thresholds based on vehicle type and weight
- Calibrate system for vehicle's specific braking capabilities
- Verify sensor viewing angles meet specifications
- Adjust sensitivity settings per fleet safety protocols
- Configure system warning timing (early/medium/late) based on fleet requirements
- Calibrate integration with stability control system
- Verify sensor height and angle measurements match specifications
- Perform static calibration procedures in controlled environment
- Conduct dynamic calibration during road testing
- Document all calibration values for future reference
5. System Testing and Verification
- Perform diagnostic scan to confirm no system error codes
- Verify all sensors report correct status
- Test warning system functionality (visual, audible, haptic)
- Confirm proper operation of driver override capabilities
- Verify system deactivation procedure functions correctly
- Test system reactivation after driver override
- Confirm proper operation in various lighting conditions
- Verify system does not activate during normal braking
- Check for false activations during normal driving scenarios
- Test low-speed functionality in controlled environment
- Verify highway-speed functionality during road test
- Document all test results with appropriate metrics
6. Documentation and Driver Training
- Complete all installation documentation with technician certification
- Record all component serial numbers in vehicle records
- Document all calibration settings and test results
- Create driver operation guide specific to installed system
- Provide fleet manager with system maintenance requirements
- Update vehicle maintenance schedule to include AEB system checks
- Register system with manufacturer for warranty and updates
- Schedule driver training session for proper system understanding
- Document system limitations for driver awareness
- Create incident reporting protocol for AEB activations
- Update vehicle safety compliance documentation
- File installation certification for insurance and regulatory purposes
Step-by-Step Installation Procedure
Preparation Phase
Begin by confirming the selected AEB system is fully compatible with the vehicle make, model, and year. Review any required modifications to the vehicle's existing systems. Verify the vehicle's electrical system can support the additional load from the AEB components without affecting other critical systems.
Document the vehicle's current state, including photographs of installation areas, diagnostic scans of existing systems, and brake performance testing to establish a baseline. Back up all ECU data before proceeding with any modifications to vehicle systems.
Clean all mounting surfaces thoroughly. Remove any trim pieces or components that may interfere with installation. Protect interior components from damage during the installation process. Disconnect the battery if required by the installation manual.
Hardware Installation
Install radar sensors in specified locations, typically behind the front bumper or grille, ensuring proper orientation and securing with manufacturer-provided brackets. Mount camera systems, usually at the top center of the windshield, verifying correct positioning relative to the vehicle centerline and horizon.
Mount the AEB control module in a protected location, typically inside the vehicle cabin or in a sealed compartment. Ensure the module is oriented according to specifications and secured to prevent movement or vibration damage during vehicle operation.
Route all system wiring following OEM-like paths, protecting from heat sources, moving parts, and potential abrasion points. Make all electrical connections according to the system wiring diagram, ensuring proper terminal crimping, sealing, and securing. Connect the system to the vehicle's CAN bus following the specified protocols.
Connect the AEB system to the vehicle's braking system as specified in the installation guide. This may involve integration with the existing ABS/ESC module or installation of a supplementary hydraulic unit. Ensure all brake line connections are secure and free of leaks after installation.
Calibration and Testing
Reconnect the vehicle's battery and power up the system for the first time. Verify the system initializes correctly without error codes. Check all power and ground connections if initialization fails or errors occur.
Follow the manufacturer's specific calibration procedure for each sensor. For radar sensors, this typically involves alignment using specific targets at defined distances. For cameras, calibration usually requires positioning the vehicle at a precise distance from calibration patterns. Document all calibration measurements and settings.
Perform all required static tests of the system, including diagnostic scans, sensor status verification, and warning system functionality. Confirm all components communicate properly with each other and with the vehicle's existing systems.
Conduct a comprehensive road test following the manufacturer's testing protocol. Verify the system activates appropriately at different speeds. Check for proper warning sequences and braking intervention in controlled scenarios. Document all test results with timestamps and conditions.
Complete all required documentation, including installation checklist, calibration values, test results, and technician certification. Register the system with the manufacturer if required. Prepare driver education materials specific to the installed system.
| AEB System Type | Key Installation Considerations |
|---|---|
| Radar-Based Systems | Require precise alignment and calibration; sensitive to bumper modifications or aftermarket components |
| Camera-Based Systems | Windshield clarity and wiper operation critical; sensitive to windshield tint or replacement |
| Combined Radar/Camera Systems | Most complex calibration requirements; typically offer highest performance and redundancy |
| Lidar-Based Systems | Require clean sensor surfaces; may have special mounting considerations for optimal performance |
| OEM-Integrated Systems | Typically require dealer-level diagnostic tools; may have specific programming requirements |
Conclusion
Proper installation and calibration of Automatic Emergency Braking systems is critical to ensuring these life-saving technologies perform as intended. Following this comprehensive checklist helps guarantee that each component is correctly installed, calibrated, and tested before the vehicle returns to service. Remember that AEB systems require periodic maintenance and recalibration, particularly after windshield replacement, front-end repairs, or alignment changes. By implementing thorough installation practices now, fleet operators can maximize the safety benefits of these advanced systems while ensuring regulatory compliance and potentially reducing insurance costs.
Streamline Your AEB Installation Process with HVI
While paper-based installation documentation has been the industry standard, forward-thinking fleet operations are now embracing digital solutions like the HVI App (Heavy Vehicle Inspection and Maintenance software). This powerful platform transforms AEB system installation management in several critical ways:
- System-Specific Digital Checklists: HVI provides customized installation guides for each AEB system type, ensuring technicians follow all required steps regardless of experience level or system complexity.
- Calibration Documentation: Technicians can record all calibration measurements, settings, and procedures directly in the app, creating comprehensive digital records for compliance and future reference.
- Photo and Video Evidence: The HVI App enables technicians to attach photos and videos of key installation steps and completed work, providing visual verification of proper procedures.
- Integration Testing Records: Document all testing procedures and results in structured digital format, enabling easy verification of system functionality and performance metrics.
- Maintenance Scheduling: Automatically generate recommended maintenance schedules for installed AEB systems, ensuring ongoing calibration checks and system verification.
- Fleet-Wide Compliance Tracking: Monitor AEB installation status across your entire fleet, with instant reporting capabilities for regulatory compliance and safety programs.
- Digital Vehicle History: Maintain complete records of all safety systems installed on each vehicle, accessible instantly for maintenance planning, warranty claims, or incident investigation.
- Technician Certification Tracking: Verify and document that all AEB installations are performed by properly trained and certified technicians, supporting quality assurance programs.
The HVI App eliminates the limitations of paper-based installation records while substantially improving documentation quality, accessibility, and compliance verification. Organizations implementing HVI for safety system installations typically report significant improvements in installation consistency, reduced calibration errors, and enhanced regulatory compliance.
Prioritize safety, ensure system performance, and maintain comprehensive documentation—AEB system installations powered by HVI technology create the foundation for advanced fleet safety programs and optimal collision avoidance functionality.
