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A Note on Automobile Cruise Control Faults and Sudden
Acceleration [or Unintended Acceleration]
by Dr Antony Anderson
C.Eng
FIEE
4. Cruise Control :
functional aspects and possible modes of failure
Most cruise control systems are functionally very similar and
appear to be of the "proportional + integral" type of closed loop
control system. Cruise control systems are likely to exhibit
similar failure modes and have the same potential for exhibiting
suboptimal performance as other industrial and domestic PI control
systems.
Block diagram of cruise control system
showing some areas of vulnerability
The automobile engine compartment is a particularly
unfavourable environment in which to expect sensitive electronics to
operate reliably:
- It is hot, dirty, humid and vibration levels are high;
- Radio Frequency Interference (RFI) levels can be high;
- There can be appreciable shock loadings that may damage
PCB wiring;
- Connectors can become dislodged or distorted or contacts
be subject to fretting fatigue;
- Wiring, if not properly restrained, can be rapidly damaged
by vibration-induced fretting;
- Servicing of the vehicle, involving the removal and
replacement
of components, may result in displacement or damage to wiring or
unwitting
damage to connectors or sometimes the wrong connections being made..
In such a hostile environment, intermittent electrical,
mechanical and electronic faults in the cruise control system would
scarcely be surprising. Such malfunctions might be permanent once-only
events, requiring the replacement of a "dead" module, or they
might be intermittent, occuring randomly, once in a blue moon.
Typical failures might be caused by :
- Sensors, switches, connectors and wiring :
- a speed sensor or its wiring may fail;
- electrical switches may fail to open or fail to close;
- electrical switches may become mispositioned, loose or
fall off;
- multiplexed switches, where several switches communicate
with a
control module over a single wire, may not switch correctly in the
presence
of a high-resistance joint or earth contact
- electrical connectors may fail open circuit or short
circuit;
- electrical switches or wiring may overheat causing
damage;
- slip ring connections (to steering wheel switches, for
example)
may become intermittent or fail;
- earthing connections may become intermittent or fail;
- presence or absence of extreme cold/ heat, moisture,
pollution,
road salt etc. may play a significant role here.
- The Cruise Control Module :
- electronic components may fail;
- vibration, shock or thermal cycling; may cause
intermittent open or short circuits on PCBs;
- moisture and surface contamination may cause
electrical tracking across insulating surfaces, in turn causing :
- the speed reference signal to drift, either up or down;
- a high gain amplifier or integrator, or digital
equivalent, to drift into saturation;
- logic may be affected by transient signals/noise;
- logic may lock on or lock off.
- a microprocessor may get into an endless processing loop
- The throttle actuator
- There are various different kinds of actuator used (
electro-pneumatic and electro-mechanical) but they are all essentially
power amplifiers, converting a small control signal into throttle
movement. The result of an input signal, whatever its source, will be
movement of the throttle. Spurious control
signals may derive from many sources including :
- RF noise at the input;
- false signals from a malfunctioning cruise control
module;
- stray potentials resulting from perhaps poorly earthed
components elsewhere in the engine compartment;
- wiring faults.
- The actuator has mechanical elements that have the
potential to
jam in any position from fully closed to fully open.
This list of possible root causes of failure is lengthy,
but is by no means complete. It illustrates however the
importance of not jumping to premature conclusions as to the likeliest
cause of any particular event. Broadly speaking, fault mechanisms may
be divided into two kinds:
- external to the cruise control/actuator modules (external
fault mechanisms)
- internal to the cruise control/actuator modules (internal
fault
mechanisms)
A fault may arise from the interplay of a wide variety of combinations
of external and internal fault mechanisms.
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