This is one those 1960s events you may actually remember: In Stanley Kubrick’s science fiction classic, “2001: A Space Odyssey,” a mainframe computer decides its space ship’s mission to Jupiter is too critical to remain in the hands of the ship’s human crew. The renegade computer, named HAL, takes things into its own hands, quietly squelching off life support for the sleeping humans. It’s a machine with a mind of its own. The remaining human (played by Keir Dullea) seizes control of the spaceship, violently, pulling out HAL’s computer memory banks.
Is there something familiar here? Picture this: You’re driving your car toward a busy intersection and instinctively take your foot off the gas pedal. Your electronically-controlled car, another machine with a mind of its own, decides it would rather not slow down. In fact, it decides to speed up…
A guest editorial in this morning’s (Feb 28) Los Angeles Times by muckraker Ralph Nader says that claims about “unintended acceleration” have been mounting since the 2002 the introduction of the Electronic Throttle-Control System (ETCS) on certain Toyota and Lexus models. He blames the problem on a lax and underfunded National Highway Traffic Safety Administration (NHTSA). “NHTSA's motor vehicle safety budget is a mere $140 million,” Nader says. “Taxpayers will pay more than four times as much — about $675 million — to guard the U.S. Embassy in Baghdad.” The NHTSA opened several investigations, Nader says, but closed them without action.
In interests of full disclosure, I’ve owned two Toyotas and I believe these cars — even the recall models — are safe. By the same token, I believe air travel is safe. It’s as statistically close to 100% as any piece of machinery can get. But that doesn’t mean a plane doesn’t fall out of the sky from time-to-time, for seemingly inexplicable reasons. Every time that happens, the airlines devote a ton resources to finding out how this occurred, and how it could be prevented from reoccurring in the future. It seems that Toyota is guilty of not acknowledging the acceleration problem sooner and is being pillared in public.
As an electronics industry supporter and enthusiast, I’d really hate to think that Toyota’s problems are electronic. It would be a black mark for all of us. David Strom had quoted me in the “New York Times” as saying the modern automobile has more computing power than the average small office. But that may not be a good thing as evidence is starting suggest that Toyota’s sticky gas pedal is not a metal shim problem or a floor mat problem. It looks like a runaway microcontroller — and it will not easily go away.
Proselytizing automotive electronics
Toyota’s Electronic Throttle-Control System adds motorized assist to the mechanical gas pedal assembly. A microcontroller (undoubtedly a pulse-width modulator) sends out complementary pulses to a pair of power transistors. The power pulses drive a multi-phase electric motor, what Toyota calls a “rotary solenoid.” Acceleration would be increased by stepping up the frequency and/or duty cycle of the pulses. If this is the cause of unintended acceleration, we’d want to know what is pumping up the pulse rate. A number of engineers have suggested this could be a consequence of electro-magnetic interference (EMI), which could artificially ramp up the microprocessor clock speed, or encourage the solenoid to register more pulses than were actually sent to it. But I have a hard time believing the ETCS wasn’t carefully engineered to minimize this kind of interference.
Audi had a problem of unintended acceleration with its Audi 5000 models back in the 1980s, which many believe was a sensor interface problem. But Audi refused to acknowledge it may be a problem with their machinery, citing “driver error” instead. The bad press, including a sensationalist “60 Minutes” story on CBS, nearly bankrupted the German car maker, and certainly kept them out of the American market for several decades.
I’d like to think the automotive industry has come a long way in its acceptance of semiconductor electronics. I remember the charismatic Alex Lidow describe the electronic motor assist system his company was developing to create more efficient autos — before an accounting scandal at International Rectifier forced him to “fall on his sword.” I remember Infineon engineers, after they took over the Sears Point Raceway, taking about the issue of fail-safe software. “You can’t have an ‘hour glass’ suddenly appear on your screen in the middle of a high-speed turn,” they told me. Like the electronic voting machines introduced and then pulled by Diebold, there are inevitably certain embedded processes that should be looked at again and again and again.
Infineon spent a lot money and energy, mid-decade, promoting its leadership position in automotive electronics. Gartner’s 2008 market share compilation lists Infineon as the world’s second largest supplier of automotive semiconductors, behind Freescale. STMicrolectronics was the third largest supplier in 2008; Renesas and NEC were fourth and fifth, respectively. I have no idea which (if any) of these manufacturers supports Toyota, who, in fact, has its own IC manufacturing. (I believe this is devoted to power transistors, and not microcontrollers.)
The automotive industry has actually embraced the use of semiconductors in a big way. Even in 2009, where a lack of credit and consumer confidence causes auto sales to implode, the automotive sector consumed some $15 billion in semiconductors (down from the roughly $20 billion consumed in 2008). Despite bewildering price decreases for all types of semiconductor devices, the semiconductor content of all the typical “light vehicle” has remained steady — about $500 — during the past 10 years. The largest content growth in recent years has come from console electronics —GPS-based navigation aids, and infotainment electronics — but future growth will come from safety systems, such as automotive radar and collision avoidance systems. Semiconductor consumption by the automotive industry will return to 2008 levels in 2011 and reach $22 billion by 2014.
My relationship with GM
My relationship with GM
I squirmed at the thought of the Federal government bailing out General Motors, though injecting stimulus money struck me as analogous to the process of inoculating a cat — you have put the needle somewhere. I similarly squirmed when George Bush senior, who claimed Republican “lassie faire” economics wouldn’t distinguish between potato chips and computers chips, nonetheless accompanied American auto industry execs on a crusade to Japan.
I have not been fan of General Motors, although their Buick model appears very popular in China. GM’s finance arm (full disclosure once again) GMAC, holds the mortgage on my house in New Jersey. (Shortly after I refinanced, a GMAC telemarketer called me to say, since my credit was so good, they were prepared to offer me a GMAC-endorsed Master Charge card. Build enough points on the card, the marketer told me, and I would qualify for a 5% discount on a General Motors car…) Ask me sometime where I am with the Chevy Volt.
I should give credit where credit is due: GM has been pretty aggressive in deploying passenger sensing systems which modulate the force with which airbags are deployed, in an effort to protect young children. It’s taken the company awhile to recognize the virtue of electronic systems in cars. Early in my career as an electronics trade journalist, I visited engineers at Delco Electronics in Kokomo Indiana. Delco (now Delphi Systems), then under the General Motors umbrella, was developing their own console radios, engine controls — and they fabricated many of their own parts (including power transistors) in-house. They showed me some of the advanced systems they were working on, and I frankly was impressed with their brilliance. I asked about the apparent time lag between the design of these systems and their actual incorporation in cars. Why wasn’t GM more aggressive about incorporating the technology their own subsidiary was developing? I wondered.
My hosts were very humble and accommodating: “We’re just the tail on a Big Dog,” they told me. “The Dog understands internal combustion engines and gear trains — but not much else.”
I’m wondering now, with Toyota having displaced GM as the world’s largest car maker, whether it hasn’t turned into what those engineers would have called ‘The Big Dog.’ q