Rebuilding the FWD Test Vehicle after a Major Accident

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Rebuilding the FWD Test Vehicle after a Major
Accident

• Albert Oyerly, P.E.
• Kenneth Hallgren
• Kansas Department of Transportation

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• Wreck involving the FWD tow vehicle
• Getting a temporary replacement vehicle outfitted
  to run the FWD
• Outfitting the permanent replacement vehicle for
  the FWD
• Modifications of the FWD

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Wreck Information

• Morning of May 24, 2002
• Intersection of K-268 and Croco Rd
• First major wreck with the FWD in Kansas

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Wrecked Suburban
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Wrecked Suburban
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Wrecked Suburban
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Wrecked Suburban
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Outfitting a Replacement Vehicle

• Objectives
• Get FWD running as quickly as possible
• Minimal vehicle modification
• Assure that data quality was maintained

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Temporary Replacement
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Outfitting a Replacement Vehicle

• Finding and Outfitting a Vehicle
• 1992 ¾ ton Chevrolet Suburban
• About 60 hours of labor
• Ready to go in about a week
• Except

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Problems Encountered

• FWD 9000 System Processor would not communicate
  with the trailer.
• Vehicle Problems encountered later on during
  testing

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Communication Problem Solving

• Started by checking all connections
• Then checking continuity on all the cables
• Especially the Multi-signal cable
• Communication problem was still not solved

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Trouble Shooting

• Last resort was to start switching cables from
  one FWD to another
• Problem ended up being a DMI display cable was
  pinched and severed a wire

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Vehicle Problems

• Overheating because of lack of Auxiliary Cooling
  Fan
• Alternator bracket kept failing
• New Exhaust System needed
• Worn-out Tires
• Tired Air-Conditioning System
• Radio did not work very well

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Permanent Replacement Vehicle

• 2003 ¾ ton Ford Extended Cab Pickup
• About one month to set up
• Completed in-house by operator

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Permanent Replacement Vehicle
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Interior of New Vehicle
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Interior of New Tow Vehicle
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Modifications of FWD

• New Axles for the Trailer
• Eliminated Shock Absorbers
• Cost of 1500
• Labor was done in-house by operator

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Old Axle Style
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New Axle Style
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Modifications of FWD

• Installation of trailer mounted generator
• Eliminates the need for 2nd alternator on tow
  vehicle
• Makes the transition to a new vehicle easier
• Cost was about 10,000
• Labor was completed in house by the operator

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Trailer Mounted Generator
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Generator Cover
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Current Setup
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Future Modifications

• Fall 2003
• Reconditioning of FWD 109
• Competed by Dynatest
• Budgeted for about 50,000

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Future Modifications

• Fall 2005
• Reconditioning of FWD 122

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Finished Product
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• Thanks
• Any Questions