NASA Engineering and Safety Center Technical Assessment Report
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Version: NASA Engineering and Safety Center 1.0 Technical Assessment Report Title: Page #: National Highway Traffic Safety Administration 1 of 177 Toyota Unintended Acceleration Investigation Technical Support to the National Highway Traffic Safety Administration (NHTSA) on the Reported Toyota Motor Corporation (TMC) Unintended Acceleration (UA) Investigation January 18, 2011 NESC Assessment #: TI-10-00618 NASA Engineering and Safety Center Version: 1.0 Technical Assessment Report Title: Page #: National Highway Traffic Safety Administration 2 of 177 Toyota Unintended Acceleration Investigation Report Approval and Revision History Approval and Document Revision History NOTE: This document was approved at the January 13, 2011, NRB. This document was submitted to the NESC Director on January 19, 2011, for configuration control. Approved Original Signature on File 1/19/11 Version: 1.0 NESC Director Date Office of Primary Version Description of Revision Effective Date Responsibility 1.0 Initial Release Michael T. Kirsch, 1/13/11 NESC Principal Engineer, LaRC REDACTION NOTE Since public release of this report on February 8, 2011, the Agency has revised its redactions to the document to release certain material previously deemed confidential under U.S.C. § 30167. This document, which was posted April 15, 2011 to NHTSA’s web site, replaces the one posted previously and contains the Agency’s revised redactions. NESC Assessment #: TI-10-00618 Version: NASA Engineering and Safety Center 1.0 Technical Assessment Report Title: Page #: National Highway Traffic Safety Administration 3 of 177 Toyota Unintended Acceleration Investigation Table of Contents 1.0 Notification and Authorization .................................................................................................. 9 2.0 Signature Page .......................................................................................................................... 10 3.0 Team List ................................................................................................................................... 11 4.0 Executive Summary .................................................................................................................. 13 5.0 Objective and Scope ................................................................................................................. 18 5.1 Vehicle and MY Selection .......................................................................................................... 18 6.0 Analysis ..................................................................................................................................... 19 6.1 Approach .................................................................................................................................... 19 6.2 Analysis of UA VOQs ................................................................................................................ 23 6.2.1 Sources of Information Relating to UA ...................................................................................... 23 6.2.2 Characteristics of the VOQ Data ................................................................................................ 25 6.2.3 Relationship between VOQs and Changes in Vehicle Design ................................................... 29 6.2.4 Classify UA Events to Identify Candidate Failure Modes ......................................................... 30 6.2.5 Warranty Data ............................................................................................................................. 36 6.3 Human Factors on UA Events and Current Trends in Automotive Technologies ..................... 41 6.3.1 Standardization versus Brand Identity ........................................................................................ 41 6.3.2 Reduction of Perceptual Feedback to the Driver ........................................................................ 43 6.3.3 Unintended Consequences of Design Decisions ........................................................................ 44 6.3.4 Migration Toward Shared Control Authority ............................................................................. 44 6.3.5 Challenges of Studying the Human Factors Contributions to UA Events in the Lab ................. 46 6.4 System Overview ........................................................................................................................ 47 6.4.1 System Design ............................................................................................................................ 49 6.4.1.1 Throttle Body Assembly ............................................................................................................. 51 6.4.1.2 Engine Control Module .............................................................................................................. 53 6.4.1.3 Accelerator Pedal ........................................................................................................................ 57 6.4.2 Throttle Control and Effects on Acceleration and Braking ........................................................ 58 6.4.3 Summary of Hardware Evolution ............................................................................................... 60 6.4.4 The Role of Diagnostic Trouble Codes ...................................................................................... 62 6.5 System Fail-Safe Architecture .................................................................................................... 64 6.5.1 System Redundancy ................................................................................................................... 66 6.5.2 System Failures ........................................................................................................................... 68 6.5.2.1 System Level Functional Fault Tree ........................................................................................... 71 6.5.2.2 System Level Failure Responses ................................................................................................ 73 6.5.2.3 System Fail-safe Modes .............................................................................................................. 79 6.5.3 Failure Mitigation ....................................................................................................................... 80 6.5.3.1 Limp Home Mode, Throttle Valve Control Limited .................................................................. 80 6.5.3.2 Engine at Idle .............................................................................................................................. 82 6.5.3.3 Disable Throttle Motor, Throttle held at 6.5 Degrees Spring Loaded Detent ............................ 82 6.5.3.4 Idle Mode Fuel Cut, Engine Speed limited <2500 rpm .............................................................. 82 6.5.3.5 Engine Off Fail-Safe ................................................................................................................... 83 6.6 Functional Areas with Functional Block Diagrams, Test Scenarios, and Test Results .............. 83 6.6.1 Throttle Position Control Functional Area ................................................................................. 87 6.6.1.1 Detailed Implementation Description ......................................................................................... 87 NESC Assessment #: TI-10-00618 Version: NASA Engineering and Safety Center 1.0 Technical Assessment Report Title: Page #: National Highway Traffic Safety Administration 4 of 177 Toyota Unintended Acceleration Investigation 6.6.1.2 Throttle Control Loop Sensitivities and Postulated Faults ......................................................... 91 6.6.2 Accelerator Pedal Control Functional Area ................................................................................ 95 6.6.2.1 Detailed Implementation Description ......................................................................................... 95 6.6.2.2 Pedal Control System Sensitivities and Postulated Faults .......................................................... 99 6.6.2.3 Evaluation of Consumer VOQ #10304368 ............................................................................... 112 6.6.3 Idle Speed Control Functional Area ......................................................................................... 127 6.6.3.1 Detailed Implementation Description ....................................................................................... 127 6.6.3.2 ISC Engine Coolant Temperature ............................................................................................. 128 6.6.3.3 “Idle On” Fuel Cut Function..................................................................................................... 129 6.6.3.4 Idle Speed Control System Sensitivities and Postulated Faults ................................................ 129 6.6.3.5 Engine Coolant Sensor Fault .................................................................................................... 129 6.6.3.6 Engine Speed Signals Corruption ............................................................................................. 129 6.6.3.7 Failed Compensation for Additional Engine Loads ................................................................. 130 6.6.3.8 Summary of Idle Speed Control Potential Faults ..................................................................... 132 6.6.4 Cruise Control