EDR Durability and 49CFR563 Presented by: Wade Bartlett, PE January 19-21, 2007 Houston Texas Outline EDR Survivability Requirements in Rule 563 EDR requirements in other transport modes Component tolerance to impact Real crash environments & those in the Rule Above & Beyond the Rule Some NHTSA-SCI SCI cases Wade s prediction for Rule 563 survivability 1
Rule 563 Issued August 2006, effective 09/01/2010 No new tests FMVSS 208: Frontal up to 35mph, Offset 25mph 214: Lateral crabbed MDB 33.5mph Record data & complete file = YES Downloadable for 10 days Engine OFF (so not all elements req d.) Some History & Other EDRs 1920s Flight Data Recorder - Historical 2
Some History & Other EDRs 1960s: Flight Data Recorders Dr. David Warren pioneered crashworthiness after de Havilland Comets started falling out of the sky Mechanical components, metallic foil, scribes 100g for 5ms.. V=7mph Some History & Other EDRs FDRs moved to tape, then solid state 1980 s 3,400g 6.5ms, V=309mph 3
Some History & Other EDRs Railroads have had EDRs for a long time Crashworthiness requirement is recent 55g for 100ms OR 23g for 250ms ( V=80mph) Short- and long-term heat or flame tolerance Static crush loading Immersion in several fluids Water at pressure to 50 or 100ft depth Some History & Other EDRs NHTSA Truck & Bus EDR Working Group Recommendations in 2001 included Locate EDR to maximize survivability Shock of 300g for 50ms ( V=210mph) -40 degrees for 8 hours 8hr immersion: water, salt water, fuel, oil Penetration (200lb, 3ft drop, ½ dia point) Static load of 500lb Fire not really a priority http://dmses.dot.gov/docimages/pdf1a/183185_web.pdf, Docket NHTSA-2000-7699 4
Current EDRs = PCB EDR Guts Getting Tougher As surface mount components get smaller, the forces go down Sealing openings & back more common. 5
Everyday Electronics Are Durable Electrical components commonly spec d to tolerate short 1000g pulses or more Floor-drop typically 2ms Laptops available to take 15g sustained and drops from 3 feet ( V=15mph) Everyday Electronics Are Durable Dancing > 4g over 250ms DV=12mph 6
Crash Pulse Half-Sine wave the most common model Crash Environment Half-Sine fit to Ford E150 @30mph 7
Crash Environment Half-Sine wave fit to Hyundai Excel @29.6mph Crash Environment Avg. US Crash Speed ~34mph (Wolf & Bratton) Avg. UK Crash Speed = 22mph (http://www.thinkroadsafety.gov.uk/campaigns/childcarseats/summary.htm) 8
Crash Environment These are only the reported crashes Avg V~12mph Leonard Evans, Injuries in Crashes - Reported Compared to Actual, SAE 2005-01-0294, 0294, http://www.scienceservingsociety.com/p/157.pdf Crash Environment How fast are people going when they get hurt? 9
Crash Environment FMVSS Tests: #3851 2002 Avalanche Frontal Barrier @35mph, V=42mph Crush~20 10
FMVSS Tests: #3851 FMVSS Tests: #3851 11
FMVSS Tests: #4777 2001 Buick LeSabre, stationary Side Impactor @33mph per FMVSS 214 Video 4777a FMVSS Tests: #4777 X peak = 8g Y peak = 16g Z peak = 25g 12
FMVSS Tests: #4777 FMVSS Tests: #4777 Crush ~ 14.4.Won t intrude in EDR space 13
FMVSS Tests: #4777 V-lat=12mph, V-long=3mph Non-deployment file FMVSS Tests: #4437 Offset Frontal 25mph, V=31mph (videos) 14
FMVSS Tests: #4437 Resultant accel from raw X & Y data FMVSS Tests: #4437 Download successful (captured 26mph of 31mph) 15
FMVSS Tests Charts from Hollowell, Gabler, Stucki, Summers, Hackney, October 1999, Updated Review of Potential Test Procedures for FMVSS 208 http://www-nrd.nhtsa.dot.gov/pdf/nrd-11/airbags/fmvss_208_ii.pdf FMVSS Tests & Real World 16
FMVSS Tests & Real World 30mph 208 Barrier Test Crush (modified from Hollowell) Lateral Tests & Real World Delta Vs for IIHS Side Impact Crash Tests and Their Relationship to Real- World Crash Severity, Raul A. Arbelaez, Bryan C. Baker, Joseph M. Nolan, IIHS, 19 th ESV Conf, Paper 05-0049. 2005. 17
FMVSS Testing NHTSA working group put it to the test 15 cars, 2 vans, 2 pickups, and 2 SUVs 3 FMVSS 208 5 side NCAP tests 13 frontal NCAP tests Generally good agreement with test equip. 21 of 21 = GOOD: No failures noted FMVSS etc. Testing Neihoff et al. reviewed 37 crash tests FMVSS plus several IIHS 40mph tests Modules from 3 OEMs Where Vetronix not able to access EDRs, OEMs had to do downloads, and declined to share some data. The paper says they malfunctioned but really, we don t know. Generally good agreement on accel pulse, and 100% accuracy on seatbelt status. 18
FMVSS Test #4955 Beyond the Rule Oblique Car-to-Car, both 35mph Cadillac V~25mph (videos) Accel FMVSS Test #4955 Beyond the Rule 19
FMVSS Test #4955 FMVSS Test #4955 Download misses some of the pulse (stops at 19mph) 20
FMVSS Test #4955 Beyond the Rule NHTSA SCI: the Real World (1) Malibu into tree 21
NHTSA SCI: the Real World (1) EDR says V=46mph (full printout not provided) http://www-nass.nhtsa.dot.gov/scireports/393025904/rpt393025904.pdf NHTSA SCI: the Real World (2) Malibu Severe Underride, EDR says V=50mph 22
NHTSA SCI: the Real World (3) 2000 Saturn (CV) hits ML320 (V3) Speed limit 55mph http://www-nass.nhtsa.dot.gov/scireports/411053793/rpt411053793.pdf NHTSA SCI: the Real World (3) 23
NHTSA SCI: the Real World (3) Saturn EDR says speed=52mph, V=41mph NHTSA SCI: the Real World (4) 2000 Silverado v. 98 G20 van PU coming towards camera Rural highway Right-hand hand curve Skids on right side from Van 24
NHTSA SCI: the Real World (4) 50 inches crush on right front corner WB shortened 38 R and 6 L NHTSA SCI: the Real World (4) 71-72mph 72mph 25
NHTSA SCI: the Real World (4)...This graph charts the case vehicle s max velocity change of 52mph which occurred 110ms after the crash was detected. NHTSA SCI: the Real World (5) One Immovable Object. 26
NHTSA SCI: the Real World (5) 2000 Buick Regal traveling 60mph http://www-nass.nhtsa.dot.gov/scireports/39550/rpt39550.pdf NHTSA SCI: the Real World (5) Result: 40+ inches front crush 27
NHTSA SCI: the Real World (5) EDR says 60mph closing speed WOT 4 seconds prior No seatbelt. but he lived. NHTSA SCI: the Real World (6) Corvette Pre-tree speed 73mph, brakes on 1 sec V=47mph @ 120ms, when power loss occurred 28
NHTSA SCI: the Real World Several high- V crashes involving 2000-20012001 Fords had loss of power during the crash, which lead to no file written to module My test subjects +1 29
Immersion Fresh water immersion & soak, 2 weeks Salt water immersion & soak, 2 weeks Fresh water frozen solid 2 weeks Most units had some water intrusion (despite having factory plugs installed) After: allowed to dry, some cases removed All downloaded before & after Fresh Water - 3 months in FL swamp 1998 GMC Jimmy 30
Download successful. 31
Chipped out of Junkyard Ice courtesy John Meserve Download successful. Fire Example Courtesy of Anonymous 32
Fire Example Download successful. 33
Big Crash: Outer case fractured Download successful. Fire/Rescue Damage 98 Chevy Monte Carlo Damaged by rescue personnel Peeled open case, component torn off board, pins pulled from plug Pins reinserted into yellow plug housing Courtesy of Robert Burns 34
Fire/Rescue Damage Fire/Rescue Damage Download successful. 35
Wade s Prediction EDRs have already shown themselves to be capable of meeting the requirements outlined in Rule 563 and more, even without OEMs paying attention to durability in this fashion. Things will only get better. EDR Mortality There are things that even EDRs can t be expected to survive. 36
S-10 burned to the ground TT unit impact, burned on scene Courtesy of Chris Bloomberg Lawn Chemical Van (courtesy of anonymous) 37
Sweet Speed Shop Installation The End. 38