Product Design & Development

Toyota Silences Faulty Electronics Skeptics

By KEN THOMAS & STEPHEN MANNING, Associated Press Writers
Tuesday, March 09, 2010

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At least one outside expert said that even if Toyota's criticisms are accurate, the professor's work shows the systems that allow brakes to override stuck gas pedals can be compromised.
Dr. Matthew Schwall, Toyota's Managing Engineer of Exponent's Vehicle Engineering, speaks during a live webcast Monday, March 8, 2010, at Toyota Headquarters in Torrance, Calif. Toyota, dogged by millions of recalls and claims that it still has not fixed its safety problems, assembled a group of experts who said studies by an Illinois professor who revved Toyota engines simply by short-circuiting the wiring were flawed because they created conditions that would never happen on the road. (AP Photo/Bret Hartman) Note: The screen behind Dr. Schwall reads, "The Broadcast ABC News Video is Misleading."



WASHINGTON (AP) — Toyota, dogged by millions of recalls and claims that it still has not fixed its safety problems, took its strongest step yet Monday to silence critics who blame faulty electronics for runaway cars and trucks.

Toyota assembled a group of experts to refute studies by an Illinois professor who revved Toyota engines simply by short-circuiting the wiring. Toyota's experts say the experiments were done under conditions that would never happen on the road.

The automaker maintained its assertion that simpler mechanical flaws, not electronics, were to blame.

"There isn't a ghost issue out there," Kristen Tabar, an electronics general manager with Toyota's technical center, told a news conference at the company's North American headquarters in Torrance, Calif.

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Meeting with reporters, Toyota addressed the work of David W. Gilbert, an automotive technology professor at Southern Illinois University-Carbondale, whose work has been the basis of doubts about Toyota's mechanical fixes.

At least one outside expert said that even if Toyota's criticisms are accurate, the professor's work shows the systems that allow brakes to override stuck gas pedals can be compromised.

Toyota is mounting a public campaign to reassure its drivers about their safety and defending itself against critics who question the fix for 8 million recalled cars and trucks. Regulators have linked 52 deaths to crashes allegedly caused by the accelerator problems.

The company's fix addresses gas pedal parts and floor mats that can cause the accelerator to become stuck in the depressed position. More than 60 Toyota owners who have had their cars repaired have complained the problem has persisted.

Toyota dealers have fixed more than 1 million vehicles. But the government has warned that if the remedy provided by Toyota does not properly address the problem, federal regulators could order the company to come up with another solution.

Gilbert told a congressional hearing Feb. 23 that he recreated sudden acceleration in a Toyota Tundra by short-circuiting the electronics behind the gas pedal — without triggering any trouble codes in the truck's computer.

The trouble codes send the car's computer into a fail-safe mode that allows the brake to override the gas. Gilbert called his findings a "startling discovery."

House lawmakers seized on the testimony as evidence Toyota engineers missed a potential problem with the electronics that could have caused the unwanted acceleration.

But Monday, Chris Gerdes, director of Stanford University's Center for Automotive Research, and a consulting firm, Exponent Inc., rejected the professor's findings.

Toyota's assembled experts said the professor's experiments could not be recreated on the actual road. For example, they said, Gilbert had shaved away insulation on wiring and connected wires that would not normally touch each other.

"There is no evidence that I've seen to indicate that this situation is happening at all in the real world," Gerdes said. He added that the professor's work "could result in misguided policy and unwarranted fear."

To prove their point, Toyota officials revved the engines of cars made by competitors, including a Subaru Forester and a Ford Fusion, by connecting a circuit rigged up to the wiring of the gas pedals.

Toyota supports other research programs at Stanford's engineering school and is an affiliate of the Center for Automotive Research, but Gerdes said he came to his conclusions "with complete independence."

Gilbert did not immediately respond to messages seeking comment.

Exponent has conducted work for companies that are being sued and once determined that secondhand tobacco smoke was not cancerous. It was also hired by the U.S. government to investigate the Columbia space shuttle disaster.

Exponent officials said they were conducting an extensive study of Toyota electronics but they had not yet found any problems with the electronic throttle controls.

Toyota has been steadfast in saying the problem is strictly mechanical. Company president Akio Toyoda assured Congress two weeks ago that Toyota research had not found a link between the reports of runaway acceleration and electronics.

Instead, the company is shortening gas pedals to prevent them from becoming lodged under floor mats and inserting metal pieces the size of a stamp to keep gas pedals from sticking in the depressed position.

An outside expert, Raj Rajkumar, an electrical and computer-engineering professor at Carnegie Mellon University in Pittsburgh who studies auto electronics, said Gilbert's work raises doubts about the fail-safe systems.

"Pretty much anybody who works on electronic-based vehicle systems understands that things can go wrong," he said.

He said a number of factors could cause vehicle electronics to malfunction, including software coding errors, electrical interference and static electricity. He said technology wasn't available to prove that a system as complex as Toyota's electronic throttle control will always behave correctly.

The professor wasn't trying to prove that his test was a real-world scenario, said Keith Armstrong, a British electronic engineer and consultant who advises companies on electromagnetic interference. Instead Gilbert demonstrated that fail-safe systems may not kick in if faulty signals are sent to the throttle, Armstrong said after reviewing Exponent's report on Gilbert's tests.

Congress has more questions. The House Oversight Committee wants to look at a 2006 memo from company employees to Toyota senior management that raised concerns the automaker was taking shortcuts on safety.

In the memo, first reported Monday by the Los Angeles Times, the employees said they were concerned the processes used to build safe cars might be "ultimately ignored."

The employees warned that if Toyota failed to act, it could "become a great problem that involves the company's survival."

Toyota executives also plan to address recall issues at the company's annual suppliers meeting in Kentucky on Tuesday.

___

Associated Press Writer Greg Risling in Torrance, Calif., and AP Auto Writer Tom Krisher in Detroit contributed to this report.

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6 Comments

  • The car continued with "smoking brakes". This should not be possible according Toyota techs. Haven't we seen enough with computers that "hangs up" and are doing all kinds of "funny things". Maybe the cars are getting way too complicated, getting the "Window" disease like our more benign home computers. To be able to REALLY trouble-shoot the problem we need more than a couple of days investigation. Is the Toyota firmware made with the same quality requirements a e.g. what you find in US Air-force planes? To get to the bottom of this, somebody with major resources needs to investigate it, somebody NOT affiliated with Toyota.

  • What people who defend Toyota do not understand is that this issue is different. Anyone with any engineering education reading the accounts about sudden acceleration knows that it is a firmware/hardware problem of the electronic engine control system, and nothing to do with mechanical issues of the accelerator pedal (which minor issue in itself shows an amazing lack of quality control). Toyota by denying the obvious root cause and refusing unlimited access to the black box data acting in an irresponsible way and should be held 100% accountable, both by the buying public and the regulators. I certainly will not even consider a Toyota car until they fully investigate the root causes of these problems, disclose it and convincingly fix it. I am in the minority, probably because unlike most Americans, I do not like gambling.

  • The title of this piece is misleading, or inaccurate to say the least. Should have said "Toyota TRIES to Silence Faulty Electronics Skeptics". The attempt was hardly successful, even if it turns out in the end that they are right. Toyota needs to remember that perception is more important than just technical data.

  • The "fly-by-wire" auto industry needs to implement a redundant and diverse engine control system that addresses both embedded hardware/software failure and also driver error.

  • Toyota dealerships are infamous for their poor, exploitive,and demeaning treatment of customers. Their evident obfuscation and long-term denial of these problems, despite numerous attempts over the years by honest and anxious customers, only magnify the anger and frustration. It doesn't matter how effacing the CEO is in apology if the staff and employees of this arrogant company fail to correct their demeaning behavior and abusive practices.

  • I'm all for safe vehicles and regulations, but I'm really tired of people jumping on the "beat up Toyota" bandwagon simply for the notoriety. It's not enough that the corporate president came and fell on his sword for congress, that some industry servant needs to pull a "possible" scenario out of the air and fan the fear mongers. I have worked in both the automotive and machine controls industry for almost 40 years and I will tell you that whatever you can think of to "protect" the user will be bypassed by the user if it is not convienient for them. Every system has opportunities for alternate operation. Sixty complaints out of a million repairs. How about you run that through your stat program. Why don't we try supporting them in repairing these issues? There's a novel concept. At least they're solvent.

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