Brief Summary
- Problem: Intermittent DEF sensor faults hide until a fault code or derate hits.
- Solution: WatchTower learns each vehicle’s normal DEF behavior and flags anomalies that are validated by Master Technicians before codes appear.
- Results: High true-positive rate and detection commonly about 5 days in advance (sometimes up to 30), enabling planned repairs and fewer road calls.
Why DEF Sensor Issues Are So Tricky
A healthy DEF system keeps vehicles compliant and running efficiently. But faults like corroded wiring on a DEF level sensor can surface only at certain speeds, temperatures, or road conditions. In the bay, everything looks normal; on the route, the signal drops. That intermittent behavior delays diagnosis until a stop engine light or derate forces your hand.
What WatchTower Does Differently
Instead of waiting for a DTC, WatchTower continuously monitors DEF level, temperature, consumption rate, and related engine parameters during normal operation. It learns a baseline for each vehicle and flags patterns that don’t fit such as abrupt level jumps, “stuck” readings, or DEF usage out of line with fuel burn. Our Master Technicians review context and issue a repair plan when the anomaly is real.
How the Model Works
Fixed thresholds miss subtle or intermittent problems. WatchTower uses machine-learning anomaly detection: it learns each asset’s normal DEF dynamics, then highlights abnormal behavior under specific operating conditions. That’s how it can surface issues even when no fault code is set.
Results That Matter to Fleets
- High true-positive accuracy: When a repair plan is issued, you can act with confidence.
- Early warning: Detection typically around 5 days ahead, up to 30 days in some cases.
- Real-world catch: Progressively worsening intermittent sensor failures tied to corroded wiring, detected before the eventual derate.
Business impact: Earlier detection means scheduled service instead of road calls, fewer surprises for dispatch, and less downstream damage to the aftertreatment system.
What This Means for Your Shop or Fleet
- Move from reactive to proactive: Fix emerging DEF issues during planned PMs.
- Shorten diagnostic time: Technician-validated anomalies guide you to likely culprits (sensor, wiring, contamination, or dosing).
- Protect uptime and compliance: Avoid derates and maintain emissions compliance without drama.
Getting Started
- Run WatchTower across your assets to baseline normal DEF behavior.
- Act on validated anomalies: Use repair plans to inspect wiring, sensors, and dosing components before codes hit.
- Train your team: Pair anomaly alerts with quick training modules so techs know exactly what to check first.
FAQs
What data does WatchTower use?
Operational data already available from your vehicles including DEF level, temperature, consumption rate, and related engine parameters observed during normal driving.
Is this just another threshold alarm?
No. It’s machine learning–based anomaly detection tailored to each vehicle, not a one-size-fits-all threshold.
Who verifies the alerts?
Master Technicians review context and confirm whether an anomaly indicates a true issue, then issue a repair plan.