The future of vehicle diagnostics: Driving the transition to electric vehicles.

      The global automotive sector is undergoing one of the most significant transformations in its history. Electrification is speeding up, emissions regulations are becoming stricter in key markets, and vehicles are quickly turning into software-defined platforms.

      However, beyond the news about electric vehicles (EVs), another shift is subtly transforming the automotive landscape: the advancement of vehicle diagnostics.

      Instead of a straightforward shift from internal combustion engines (ICE) to electric propulsion, the industry is entering a dual-technology era where advanced ICE vehicles and rapidly developing EV architectures coexist. This scenario is altering the expectations for technicians, workshops, and the diagnostic tools they use.

      In this context, diagnostics has evolved beyond mere troubleshooting. It has become a fundamental infrastructure layer of contemporary automotive maintenance, enabling technicians to analyze the vast amounts of data generated by today's vehicles.

      ICE Vehicles: More Digital Than Ever

      Despite the swift rise of electrification, ICE vehicles will continue to represent a significant portion of the global fleet for the foreseeable future. The International Energy Agency reports that the global vehicle fleet has surpassed 1.4 billion vehicles, with ICE and hybrid vehicles expected to make up more than half of this fleet well into the 2030s (IEA, 2024).

      Simultaneously, combustion vehicles have developed well beyond their mechanical foundations.

      In the early 1990s, an average vehicle was equipped with fewer than 10 electronic control units (ECUs). In contrast, today’s modern passenger vehicles typically feature 70–150 ECUs, with high-end models often exceeding 200 control modules overseeing powertrain functions, safety systems, infotainment, and connectivity (McKinsey & Company, 2023).

      These systems utilize increasingly advanced in-vehicle networks such as CAN, LIN, FlexRay, and Automotive Ethernet, creating intricate electronic architectures that must work cohesively for safe vehicle operation.

      Several factors are contributing to this rise in electronic complexity:

      - Stricter global emissions regulations, such as Euro 6 and the upcoming Euro 7 standards

      - Widespread implementation of Advanced Driver Assistance Systems (ADAS)

      - More sophisticated engine and transmission management strategies

      - Connected infotainment, telematics, and over-the-air software systems

      ADAS technologies, in particular, have altered service procedures. Components like radar sensors, cameras, and ultrasonic systems require precise calibration for proper functioning. Even routine repairs, like replacing a windshield or fixing a bumper, may necessitate advanced calibration processes supported by professional diagnostic tools.

      At the same time, vehicles are producing unprecedented amounts of operational data. Connected cars can generate up to 25 gigabytes of data per hour from their sensors and control systems. For technicians, this indicates that conventional troubleshooting approaches are no longer adequate. Basic code readers lack the capability to interpret encrypted gateways, cross-module interactions, or advanced communication protocols.

      Modern diagnostic platforms must now accommodate:

      - Comprehensive multi-system scanning across numerous ECUs

      - Real-time sensor and parameter analysis

      - Module coding and software updates

      - Secure access to manufacturer-protected systems

      In summary, contemporary ICE vehicles have transformed into digital ecosystems on wheels, necessitating diagnostic tools capable of navigating increasingly intricate electronic architectures.

      EVs Present a New Diagnostic Framework

      While ICE vehicles are becoming more electronically advanced, EVs introduce a brand-new diagnostic structure focused on high-voltage energy systems and battery management. The uptake of EVs has surged dramatically. According to the International Energy Agency, worldwide EV sales surpassed 14 million units in 2023, expanding the global EV fleet to over 40 million vehicles (IEA, 2024).

      Unlike combustion vehicles, EV diagnostics emphasize monitoring electrical and electrochemical systems rather than combustion processes or emissions management.

      Key EV subsystems that require diagnostic monitoring comprise:

      - High-voltage lithium-ion battery packs

      - Battery Management Systems (BMS)

      - Electric motor controllers and inverters

      - Onboard chargers and DC-DC converters

      - Battery thermal management systems

      Most EV platforms operate on 400-volt architectures, while next-generation systems are moving towards 800-volt platforms to facilitate quicker charging and improved efficiency (Deloitte, 2023). The complexity of battery packs is significant; a single EV battery may consist of thousands of lithium-ion cells organized into modules, each continuously monitored by the BMS to ensure safe operation and maintain balanced performance.

      Consequently, EV diagnostics focuses on indicators such as:

      - State of Charge (SOC) – real-time energy availability

      - State of Health (SOH) – long-term battery deterioration

      - Cell voltage balancing

      - Thermal management efficiency

      Additionally, EV powertrains are predominantly software-controlled. Many service issues arise not from hardware malfunctions but from software calibration discrepancies, firmware bugs, or communication failures among control modules.

      This transition signals a wider change in the automotive industry. As noted by McKinsey & Company: “The vehicle is rapidly becoming a software-defined platform, where functionality is increasingly dictated by software rather than hardware.”

      For workshops and technicians, this implies that diagnostics must increasingly incorporate electrical