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Automotive Technology
The Automotive Technology Blog is the
place for conversation and discussion about electrical/electronic components, materials, design & assembly, and powertrain systems. Here, you'll find
everything from application ideas, to news and industry trends, to hot topics
and cutting edge innovations.
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Posted May 15, 2013 10:23 AM
by VickiS
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In last week's post our car doctor was checking over a Mercedes Benz 300SD that was not starting well. The two fuel filters were replaced and the fuel pre-pump was found to be leaking.
Parts Replacement
The order was placed for the new fuel pump. The old one was left on the car until the new one arrived. While waiting for it to be delivered, the spin-on and in-line fuel filters were replaced and then the bay was needed for another car. Time to move her out to the lot and wait for her new fuel pump.
Fix Me Already, OK?
Unfortunately, after getting new fuel filters, the Benz pitched a major fit and was completely unable to be started. It was suspected that after the fuel filters were changed, that the increase in fuel flow combined with the old leaking pump prevented the car from starting. That suspicion would later prove to not be the case. Because the no-start was thought to be the fault of the old pump, the car was given a time-out and left in the bay to await the new fuel pump.

Side profile picture of the fuel filter. The white NAPA piece is the spin-on fuel filter.
Fuel Pump Installation
The new fuel pump arrived and was installed in the vehicle. And still, no start. The tech went back to the basics and checked a variety of things looking for the issue. All systems were working well enough that the car should have started.
Re-Diagnosis
The tech retraced his steps on the job he did replacing the fuel filters. He found that the spin-on filter had fuel coming into it, but not going out of it. At that point, he took the filter apart completely and discovered that a bolt in the top of the filter had a check valve in it. Additionally, that screw/check valve had to align with the receiving orifice to complete the flow of fuel. The first time he installed the filter he had not aligned the check valves so the fuel could not flow freely from one orifice to the other.

Fuel filter shown closer. Line up marks drawn on both pieces.

Upper piece: black mark indicates where the fuel line is located.
Bottom piece: nut screws into top of the fuel filter. It contains a check valve, gets pushed by pressure and opens up, allowing fuel to flow through the orifices.
The tech drew black lines on top of two screws to align the two orifices. This allows the fuel to flow freely between both pieces. The Benz fired up and was good to go. She was driven away happily by her owner until the next issue needs attention.

Happy car with new fuel filters and fuel pump.
References:
Midas Hudson, NY
For Dummies
O'Reilly Auto Parts
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Posted May 08, 2013 10:00 AM
by VickiS
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Recently, a beautiful 1983 Mercedes Benz 300SD (diesel) rolled in spitting and sputtering and not wanting to start. Here's the poor patient:


The tech had a hard time getting the car started in the parking lot to get it into the garage bay, but with some coaxing and a little sweet talk, he finally managed to fire her up and move her inside.

Sad car - old dirty fuel filters not allowing it to start
Getting to Know the Patient
Car doctors need to find out what ails their patients. When a diesel engine starts sputtering, a solid first question to ask the car's owner is, "When was the last time the fuel filters were changed?"
The answer in the case of the old Benz was, "Not since I've had it", which turned out to be about 3 years. That's actually two years longer than anyone should allow fuel filters to stay in a diesel engine without changing them.
Fuel Filters 411
Most diesel engines have two fuel filters. The first one is the primary filter that's situated between the engine and the fuel tank. This filter cleans the diesel while it's on its way to the fuel transfer pump. The secondary filter is near the engine. The diesel passes through this filter before it enters the fuel injector nozzles.
Both filters should be changed at least once a year since, A) they do a lot of work cleaning the fuel, and B) diesel gels in the winter. This particular car resides in the Northeastern U.S. where winters can be brutal. If the filter is moisture bound, the fuel could freeze in the filter -- not a good situation. Mister, you are just looking to have an unhappy car if you don't maintain that diesel engine and your fuel filters! Without proper filter maintenance in a diesel engine, fuel contamination can clog the fuel injector nozzles. Now you have another problem that needs to be fixed.
Diagnosis
Our fine technician checked out the fuel filters first. The logical thought at the point of sputtering and learning the filters haven't been changed in at least three years is to look at the primary ignition parts. In this car, one fuel filter is a screw-on external filter which looked pretty old and beaten up. The second filter is covered in clear plastic which was super dirty, giving limited visibility to the interior of the filter. When new and clean you can see inside the filter, but the old one was so dirty we couldn't even show it to you* . Bottom line, these fuel filters were toast. They need to be replaced STAT!
*mechanic guy forgot to get a picture for his reporter.
In-line fuel filter - Clear plastic was very dirty. This is the new one.

Stock Image Fuel Filter
Fuel Pre-Pump also a Hot Mess
The technician saw moisture under the engine compartment area and noticed that the fuel pre-pump had fresh liquid around it. The tech pushed the primer and gas spewed everywhere. The seal between the moving parts of the primer had evidently worn out and was causing the leakage.

Pre-pump primer on fuel pump - Leaking diesel fuel from the top
Next Week:
Parts replacement and another problem. What did the car doctor do wrong? Can he get the Benz running again?
References:
Midas Hudson, NY
For Dummies
O'Reilly Auto Parts
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Posted April 24, 2013 1:50 PM
by HUSH
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Sprin g is here, and depending on your level of
automotive-consciousness it means it's time to wash, rinse and wax that
beautiful [car] body, or hope the next rainfall washes the salt and bird poop
off your hood. The first time my father taught me to wax a car was akin to a
magician handing
down his trade secrets;
and while he was no vehicular David Copperfield, he at least provided me with
some of the most basic lessons.
Change your oil and air filter regularly. Keep your tires
properly inflated and balanced, and rotate them too. Run your gears to maintain
traction in the snow. Black cars hide dirt but show scratches, and white
finishes hide scratches but reveal dirt. Don't buy red cars because they get
the most tickets.
I think Dad's knowledge will be
passed down to my kids too, but I'm hesitant to explain why red should be
avoided. When I think of a Ferrari or a Corvette, none of the other colors are
quite as sexy as red. Something also tells me that this long-held assumption is
a myth, and I'm just as likely to be hassled by Johnny Law in
a grey car as I would a red car.
Last year was the second year in a row that white was the
most common color for new cars produced. It unseated silver
in 2011, and DuPont - the largest auto paint manufacturer - cites consumer
products for the inspiration of car color trends. Silver, used heavily from
1996 to 2005 in cell phones and other electronics, came to represent advanced
pieces of technology. Tack on the development time of a typical auto paint (2
to 4 years), and the result reveals silver's popularity through 2010.
In 2012, the most popular auto colors were:
- White
- Black
- Silver
- Grey
- Red
Altogether, white, black, silver and grey make up 77% of all
car colors globally. White and black have long been the most heavily used
colors in the luxury car segment, and have now taken over the entire automotive
marketplace. Experts believe that the popularity of smartphones and tablets
have steered consumers towards black and white cars. Apple in particular
presents their innovative iPhones, iPods and iPads in dichotic black and white.
How long until we get the iCar? We'll never know.
As you can see from the graph, red cars make up just 7% of
all cars, so anything significantly disproportionate to 7% of overall tickets
would make red more or less likely to be ticketed by law enforcement. In 1990,
a reporter for the St. Petersburg Times
(Florida) conducted his own unscientific study to see how valid the notion of
'red cars get more speeding tickets' really is. He randomly sampled four
intersections in two Florida counties. Out of the 1,198 cars he recorded 14% of
them were red. He compared the results to the last 924 speeding violations in
those counties, only to discover 16% of those violations belonged to
red-colored vehicles - a rather moderate difference. However, other vehicles
had rates of violation disproportionate to their prevalence. White cars
accounted for 25% of vehicles, but received only 19% of the violations.
Similarly, silver cars were 10% of all vehicles, but received just 5% of the
violations. Unexpectedly, grey cars received 10% of the 924 violations, while
representing just 6% of the sample.
Does this indicate that it's favorable to drive a silver car
over a grey
car? Or perhaps lead-footed drivers are drawn to grey?
While
it's dangerous to make such broad assertions, car colors have also been linked
to safety and insurance rates. In 2007, the Monash University Accident Research
Centre in Victoria, Australia, published the results of a 17-year study that
found vehicles that were black, grey, and silver in color have accident rates
higher than white cars, at 12%, 11%, and 10% respectively. Red cars and blue
cars are 7% more likely t han white cars to be involved in an accident, while
yellow, beige and tans cars are virtually even with white as the safest color
choice. Researchers noted that cars that have low contrast with the road and
environment are more likely to be involved in accidents. Perhaps auto insurers
should take this information into consideration, though all of them state they
do not charge more for certain colors.
While
many people contend that red cars are discriminated against, it's often with
prejudice. Other psychology studies had concluded that purchasing decisions are
based 93%
on visual appeal, and most people prefer colors that inspire an
emotional response, or essentially your favorite colors. As such, auto paint
manufacturers like DuPont are beginning to broaden their color lineups. Green
is expected to be the next auto color on the rise. Not only does green have
resonance as an environmental term, but it is also commonly associated with
feelings of hope, happiness - and perhaps most important on a flashy ride -
envy.
So if you're really looking to avoid a second glance from
watchful eyes on the road, and you may want a little extra safety, drive a
white car. Or, if you would rather make a statement, go with something
flashy…like pink!
Resources
(Image credits: My Car Heaven; DuPont; ACE Cash Express; Fox News)
Forbes - Top 10 Most Popular Car Colors
Snopes.com - Red Handed
Car Business Today - The Facts About Safety and Car Color
KISSmetrics - How do colors affect purchases?
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Posted April 03, 2013 9:49 AM
by HUSH
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Tipperary Hill is a Syracuse, N.Y., neighborhood with a
heavily Irish heritage, and the Celtic pride of its residents has led to an
85-year-old traffic anomaly. In the 1920's, locals took offence that the new
traffic light that placed the 'British' red over the 'Irish' green, so they
took a very Irish approach: they broke it. The city obliged the neighborhood's
attitude until the state government demanded the light be hung red-side up. For
three more years the locals hurled stones at the light, until finally the city
relented and hung the light green-over-red. Today, the light remains this way
and it appears to be the only example of a green-on-top red light.
No matter how a traffic light is oriented--and no matter the
local identity--red is universally seen as "stop" in motorized countries. As
annoying as they are, red lights are imperative in creating a right of way for
drivers. And traffic lights have become commonplace on canals, in bike lanes, and
for public transport systems.
While many drivers dream about a
device that always gives
them the green light, other places are integrating computer analysis into
traffic signals. And as the traffic light is set to face its sesquicentennial
in 2018, some engineers are imaging are new, more efficient means of traffic
regulation.
The Past
The first traffic light was installed outside London's
parliament in 1868. The design was based upon a train yard signal and included
semaphore arms with integral red and green gas lanterns. The signal could be
manually rotated, and though the main advantage was increased safety for the
operator, a gas explosion maimed the police officer who ran it just a month
after it was installed. Until electric designs were invented, the traffic light
was considered too dangerous. In 1914, Cleveland, Ohio, installed the first
electric traffic light, and over the next decade many light designs
proliferated in North America. Early models were commonly mounted on pillars
within intersections. These 'dummy lights' required drivers to swerve around
them, and only exist in historic preservation instances today. Eventually,
lights began to be hung; they gained switches so a signal operator could
control multiple light sets (Salt Lake City, 1917); and lights became automated
(1922, Houston) or computerized (1968, Toronto). Excepting when countdown
timers began to appear in the 1990s, traffic light representation has been
largely unchanged.
There
is an innumerable amount of configurations for traffic lights worldwide, but
red is comprehensively seen as 'stop' in contrast to green's 'go'. The U.S.
states of California and Texas sometimes place two red lights on top of each
other, if only to gain visibility. Blustery regions of the southern U.S also
frequently use horizontal traffic lights to reduce wind resistance. Canadian
provinces commonly use horizontal designs as well, but some incorporate shapes
into the designs to aid color blind drivers. Red signals are represented by a
square; yellow by a diamond; and green by a circle. There are other unique
instances of horizontally-oriented traffic lights. Some Chinese cities utilize
a horizontal LED bar light which displays in patterned red, blinking yellow, or
shrinking green. Other Chinese states use simple red/green arrows, which can be
confusing to unfamiliar drivers. Perhaps the most random type of traffic signal
can be found in the Netherlands, which sparingly uses a nine dot grid to
represent traffic commands (at right).
The Present
Even though the methodology of the traffic light has been
stagnant for years, new concepts are beginning to invigorate this old mechanism.
Recently, Los Angeles became the first city in the world to synchronize every single
one of its traffic lights; that's 4,500 lights across 469 square miles. Los
Angeles has the second worst traffic congestion in the U.S., only behind
Washington D.C. As a result, L.A. has spent 30 years and $400 million to build
a system of magnetic sensors, traffic cameras, and computers to analyze and
predict traffic patterns in the metro area. The result is a 16% increase in
traffic speed, and a 12% decrease in delays at traffic lights. This was done in
large part to be more environmentally and economically friendly-one report
estimates fuel and time savings to be up to $1.3 billion.
The Future
As far as the future of traffic control is concerned, there
are two very different camps. In one, a visual redesign of traffic lights to
modernize them; the second, a future with no traffic lights at all.
The droplet traffic light (seen right) is an invention of a Korean
company. The idea is simple: a solar powered light operates normally, directing
vehicles in shades of red, yellow, and green. But when the light is red, it
rotates to display the news, weather, and traffic info. Before the light is up,
it rotates back to the standard color indicators and then finally lets vehicles
pass. On the other hand, residents of the Dutch town of Drachten have been
guinea pigs for an experiment in which their traffic lights have been removed
altogether. The idea, says the engineer behind the project, is to make the
roads more dangerous, thereby encouraging
people to be more wary of their decisions. Remarkably, major traffic collisions
have been exchanged for minor impacts, and traffic deaths have decreased as
well.
Personally, I don't see either of the aforementioned ideas
coming into wide acceptance. While solar powered traffic lights are definitely
smart, I don't think many municipalities are going to install small LCD
displays in their traffic lights, which will only further distract drivers. As
far as removing traffic lights altogether, that seems far-fetched as well.
Russians, in a nation with poor traffic laws but over 30 million cars, have a
dash cam in nearly every vehicle to protect personal rights. The result has
been such dash cam gold as mirror
fight; armor crossing;
and jet buzz.
What say you? What does the future of traffic control look like?
Resources
(Image credits: Roadtrippers; My Internet Security; Wikimedia; UC Davis; Yanko Design)
Wikipedia - Traffic light; Tipperary Hill
Telegraph - Is this the end for traffic lights?
NY Times - To fight gridlock, LA...
Design Boom - Psychic Factory: Droplet Traffic Light
Wired - Why almost everyone in Russia...
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Posted March 20, 2013 2:08 PM
by HUSH
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While it may be snowing across some parts of the U.S. and
Canada, spring is actually on its way away. When we steal the best sunrays from
the southern hemisphere these next few months, a number of spring and summer
traditions renew. The first pitch of baseball is upcoming; students will
receive a months-long sabbatical; and of course, the classic family vacation. Right, Clark? (language)
Pack the suitcases and head to the beach or a national park;
and fill the gas reservoir with the murky byproduct of dead dinosaurs--which
will cost you an arm and a leg. Clark, isn't this the gas tank?
While some
speculate that gas prices will recover to previous lows, it's a forecast that
seems unlikely to be accurate. Petrol prices continue to hover near four
dollars a gallon across the U.S., a country rebounding from recession.
Of course, there are alternatives to your typical octanes.
LPG and CNG vehicles are available but rare, E85 isn't worth the money,
electric vehicles are still early in their development, and some radical ideas
are still in the pipeline. While the kids ask, "Are we there yet?", here's why
you're stuck with a $100 gas bill too.
LPG and LNG/CNG
Passed are the days where LNG was considered a viable
gasoline alternative. LNG is one of the cleanest-burning fossil fuels known, so
it was envisioned as our best compromise between availability and emissions
control. Mainly, handling and infrastructure problems have limited its
availability. Liquefying and shipping LNG is expensive, and LNG can only be
transported by sea, reducing its usage to coastal areas where other gas
resources are even more expensive. Building fueling stations is equally cost
prohibitive. CNG faces similar issues, but provides less energy for the same
volume as LNG. Natural gas vehicles have found homes in the Middle East and
South America, but have not been widely adopted elsewhere.
LPG has a small worldwide market share--just 3%--and like natural
gas offers less drive range with a comparable volume of gasoline. Its
commercial availability is low, despite its ample production; LPG, also called
AutoGas, is a byproduct of crude-oil refining. LPG vehicles are often retrofit
at a cost of about $3,000, and require a bifuel engine so gasoline can also be
used when LPG is not readily available. This adds weight and a second reservoir
to the vehicle, and a dual-use engine does not achieve the best combustion
ratio for LPG.
Outside of some buses and some trucks, propane and natural
gas haven't proven to be better alternatives in North America.
E85
With nearly 2 million flex-fuel vehicles in North America,
it's clear that domestic auto manufacturers have hedged their bets on E85 to be
the best gasoline substitute available. The United States has publicly
supported E85 initiatives, and the Midwest provides an abundance of corn from
which to synthesize ethanol. E85 also is less carbon intensive, is less
corrosive to engine components, and can be derived from a variety of
resources. So why hasn't E85 caught on?
First, a careful ratio determines when it's most suitable to
purchase E85. On average, E85 provides 25% less mileage than gasoline, so it's
only logical to purchase E85 when it's less than 75% the cost of gas. Some E85
proponents argue that manufacturers aren't doing enough to maximize the mileage
of E85 gas, citing that manufacturers are reluctant to purchase the rights to
fuel sensors patented to optimize E85 mixture and combustion.
As a flex-fuel vehicle driver, I can vouch that
the capability of running E85 was an attractive selling point. Only after my
vehicle purchase did I learn that E85 was actually far more expensive per mile
than gasoline. (Not that I regret purchasing it!)
Tesla S and Chevy Volt
The two most prominent all-electric vehicles to hit North
American shores would be the Tesla Model S and the Nissan Leaf. These cars are
meant for two different market segments, with the Model S starting at $60,000
and late model Leafs starting at about $28,000; both vehicles are eligible for
thousands of dollars of tax credits. Many other all-electric vehicles have yet
to be marketed stateside.
Until very recently, the battery technology to power a whole
vehicle has remained unavailable. Oversized battery packs powered undersized
vehicles, a shortcoming to drivers who crave large cars. Furthermore, a full
charge will only provide 150 to 200 km of range before the battery has to be
recharged again, sometimes for 8 hours. Recharging infrastructure is low and no
standard charging style or method has been set. Finally, the battery packs on
electric-only vehicles will burn out, and manufacturers warranty these
batteries as they would a powertrain. Replacing one of these batteries would
cost around $10,000.
Electric cars remain on the
back-burner, at least until a breakthrough in battery size and cost occurs.
What does this mean for the family vacation? That inhaling
petrol fumes through the open window on an expanse of highway is meant to be
enjoyed for at least a decade more.
Last month, Peugot revealed plans for car that runs on
compressed air. It says that the model will be available in 2016, and it has
already driven four prototypes more than 12,000 miles. That being said, the
nonstop knock*knock*knock of a
gasoline engine was perhaps the only respite from the third singing of 100 Bottles of Beer on the Wall.
Resources
(Image credits: Retroland; LPG Vehicles UK; Examiner; Motor Trend; Autoblog)
Wikipedia - E85; Autogas; Natural gas vehicle; Tesla Model S; Nissan Leaf
ClimateTech Wiki
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Posted August 29, 2012 3:33 AM
by HUSH
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Let's
face it reader,
you probably push the speed limit of your local jurisdiction. It's estimated
that two-thirds of drivers at least occasionally speed, and the Insurance
Institute for Highway Safety believes that speeders are more often males below
age 30. Guilty.
Totally deserves every ticket he gets!...via Vincent Abry
But speed limits seem arbitrary here in North America,
especially when you have examples like the Bundesautobahn in Germany with no
speed limit and an exemplary safety record. And speed limits seem just plain
annoying after your first dozen speed tickets. Amirite?
...via Autos AOL
How do governments establish speed limits? Where are the
fastest roads? And can North America support a pseudo-autobahn? Crank the driving tunes, get
out the road maps, and tailgate HUSH in a quick look at speed maximums.
World Speed Limits
The first person convicted of speeding was Walter Arnold of
East Peckham, Kent, U.K., in 1896. Arnold had powered his 'light locomotive'
(i.e. car) to a blistering 8 mph, 6 mph faster than the legal limit. The
arresting officer gave chase by bicycle, and Arnold was penalized one shilling.
In general, speed limits have increased as automobile
engineering and road construction has improved. In 1977, Canada switched their
signs to read "MAXIMUM XX," registering the numerals in km/h. The highest
speeds in Canada reach 110 km/h (68 mph), though authorities in British
Columbia are considering 120 km/h (75 mph). China's regulations are similar.
...via Wikimedia
In the United States, speed limits are presented in mph, and
are established by state governments. Until 1999, several rural highways in
Montana had speed limits posted as "reasonable and prudent." This essentially
meant drivers were expected to be responsible, but the vague nature resulted in
an established state speed limit of 75 mph. The highest speed limit belongs to
Utah and portions of Texas, where the posted limit is 80 mph. The U.K. is the
only other country in the world using the Imperial system for speed, and they
enforce a 70 mph limit.
While the German autobahn is often cited as having no
maximum speed, only one-quarter or less of the roadways are actually limitless.
Most of the autobahn is regulated by variable speed limits and LED signs, with 120 km/h the
most popular. This offers the German system flexibility to deal with traffic
and weather issues. Indeed, the German system is also rather strict, with
constraints on tire inflation, eating and drinking, and lane occupancy.
Autobahn signage...via Wikimedia
The fastest established speed limit belongs to Abu Dhabi,
UAE, where it is 140 km/h (87 mph)--actually a 2011 reduction from the previous
limit of 160 km/h (99 mph). Poland also retains a 140 km/h limit.
Enforcing Speed Limits
Many governments establish speed limits based upon the speed
that 85% of vehicles are traveling at or below in free-flowing traffic
conditions. Traffic engineers also take into account the surrounding
environment, design, crash experiences, and pedestrians. This system isn't
perfect however, because a new 85th percentile will be established
when a new limit is posted.
Certain jurisdictions also have tolerances for speeding. In
the USA, tolerances are often up to the arresting officer, while the U.K. has a
legal tolerance of 10% of the legal limit plus 2 mph. A study covering drivers
in Canada and the USA discovered that most drivers caught speeding when over 15 mph the posted limit.
Germany has a strict tolerance of 3 or 4 km/h in favor of the driver.
Seeing a marked police car on the side of the road is no
longer the most common way method to get caught speeding. Photo enforcement
typically involves some type of smart camera or machine vision that calculates
the driver's speed between points. These unattended cameras can be placed covertly,
or legislation may require their announced presence. French authorities are
known to calculate the average speed between two tolls, and assess violations
if the speed is over the legal limit.
...via Free Republic
Furthermore, many jurisdictions enforce new editions of the
"prudent law" that requires drivers to slow down at night or in unfavorable
weather. Heavy trucks may face additional speed restrictions.
Can there be a North American Autobahn?
While the idea of a North American super-speed highway is
awesome (hello, Ferrari), it's
impossible to replicate. German motorists are more rigorously trained and the
German vehicles face additional inspection measures to ensure their safety.
That 1992 Honda rust bucket would outlawed in Deutschland.
Texas continues to push the limits of…um, speed limits, by
passing an 85 mph statute for portions of the Texas State Highway in 2012. It
is the second-fastest legal limit in the world. That same year, Italy passed
legislation allowing 150 km/h (93 mph) speeds on highways, but has not found a
road with the requirements to safely do so. And these are the Italians with all
their super cars and leather!
One of the most critical factors to overcome for a
super-speed highway would be the revenue generated by traffic violations.
Municipalities would stand to lose considerable income from decreased
violations. Insurance companies stand to profit from traffic violation
surcharges as well.
Between our substandard training, road safety
issues, and a huge loss of income for cities and towns, it is safe to say an
autobahn will not be appearing on North American anytime soon.
Resources
Gulf News - Revised speed limits in Abu Dhabi to stay
Wikipedia - Speed limit; Speed limits by country
Red Orbit - Study: Most drivers disobey speed limits
How Stuff Works - How the Autobahn Works
IIHS - Q & A: Speed and speed limits
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