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Bolt-Kabob -> [Warning --> Graphic Images]

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34K views 129 replies 41 participants last post by  Joule  
#1 ·
This is the absolute worst way to get an extra charger. Definitely not recommended.
My son and I recently had an accident in the Bolt, which had only 8k miles and was only a tad over 3 months old. Well under the 300k miles I expected.
We are both not dead, and compared to dead, we are relatively ok, with no hospitalization, no broken bones, but still stiff and sore, both have concussions, etc. The healing process is very slow. Concussions, even mild ones, come with lots of collateral effects. It remains painful for me to sit almost two weeks later.
Here are the details, as I have been able to piece together. We squarely hit the start of a guardrail, likely at 65mph. The impact was nearly on center. The edge of the guardrail is narrow in width, but tall in height. It was nearly covered by snow. We went airborne for 46 feet, I believe landing on the rear of the car (Impact 2). We then dragged the outboard wheels only through the snow for another 30 feet to impact 3, where the car dug in, ejected the right rear wheel, and pivoted about 135 degrees. We then rolled to impact 4 and continued rolling to impact 5. Final resting position was on the roof, passenger side down. Total distance was 109 feet + 26 feet lateral from first impact.
The curtain airbags deployed. (Air bags have a smell, like gunpowder, and leave the cabin smoke filled, adding to the disorientation.) The front airbags did not deploy (seems wrong). The chair airbags did not deploy (apparently those are only when vehicle perimeter is impacted upon.) My glasses ended up not on my face with the lenses not in them, most likely blown off by the airbag
The vehicle remained locked, even after coming to rest and the airbags deploying [There's a needed firmware update to auto unlock plus shift to park.]
You can see how the A frames on both sides held up well, but you can also see how far the roof and windshield collapsed.
Being an engineer who's also curious, I'm having the forensic data pulled from the airbag module, along with any other modules we can get. I'll add that printout once I have it.
I feel that before airbags, this accident may not have been survivable. With gen 1 airbags, it likely would have been two ambulance rides. With the full, modern sensor suite, it was walk (or more accurately, limp) away. So, I'm thankful that I bought the best that Chevy had available, even while I'm disappointed that all the sensors didn't work properly.
It's also not clear how this accident would have been different with no snow. Then we would have struck the guard rail, and either stayed there (and needed to dissipate all the energy in one fell swoop), or we would have dissipated most of the energy and still ended up going up and over, rolling some, etc. Just like race cars, IndyCar in particular, are designed to shed parts/deform the car to help dissipate crash energy, the snow helped to spread out how energy was being dissipated into more distance and more time, but worse angles/directions. So, a summer crash would have been different, unclear if better or worse.
I believe that my front collision did NOT detect the guardrail. I know the system was working because it has alarmed on me while on other trips. I have previously estimated front detection will shed about 1/2 your speed and thus 3/4 of your momentum from when it kicks the cruise off (if you're in L) to the point of hitting another vehicle. So, we missed out on the protection from front detection. As you know, the lane keep can't even stay in a lane that is straight and that only will put an indicator in the mirror, so that was no real help either.
As I said, I'm getting data pulled. Hopefully, that will give some answers. Based on the pictures, my forensic engineer also thinks the front airbags should have been triggered.
Here's what I would like from the group:
1. Anyone who can show me exactly where the front airbag sensors are located.
2. Recommendations on what parts I should pull before I allow the car to be sent to the salvage yard.
3. Most importantly: Does anyone have contacts to inside the Chevy team on the Bolt, ideally to the airbag/frame group. I really feel like this crash found a design shortcoming and I want to try to get it addressed. If the front bags had gone off, my son would not have hit his head on the steering wheel. I think they're relying on that bar across the front to transfer the force into the frame, but it appears to be aluminum. Instead, mine shattered. I'm not trying to sue Chevy, just to get the Bolt improved.
4. Anybody who wants to outbid the salvage yard for the car is welcome. You'd get a nearly new battery pack to build yourself a powerwall. The car is in MN.

I really loved my Bolt. It's too bad that it's gone, but I'd much rather still have my son than my car.
 

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#3 ·
Nook, I am very sorry to hear about your accident and extremely happy to hear you have only minor (considering the event) injuries. I don’t have the ambition or resources to take the remains off your hands, but I have been interested in acquiring a DCFC junction block, charge port, and wiring harness at some point. If you could let me know which salvage yard takes the car, I’d appreciate it. I’m in St. Paul.
 
#4 · (Edited)
I'm glad you weren't more seriously injured.

It looks like the snow created a ramp that added upward momentum to the car, and catapulted it once striking the railing. My guess is the impact wasn't severe enough to deploy the front airbags. There's always a balance to maintain between deploying the airbags to prevent serious injury, and not deploying to prevent unnecessary injury.

I'd say in clear conditions the car would have stopped more suddenly, and probably the front airbags would deploy. Difficult to say if injuries would be better or worse. Stopping more suddenly places more stress on the body, but then vehicles are mostly designed to dissipate that kind of energy, along with the crash attenuator on the guard rail. Crashes resulting in rollover are generally considered to be more dangerous.

Dash cam footage would have been interesting to study.
 
#36 ·
I'm glad you weren't more seriously injured.
Heck yeah!

I'd say in clear conditions the car would have stopped more suddenly, and probably the front airbags would deploy. Difficult to say if injuries would be better or worse. Stopping more suddenly places more stress on the body, but then vehicles are mostly designed to dissipate that kind of energy, along with the crash attenuator on the guard rail.
The car is NOT designed to the point where it will protect the occupants in a direct-on crash into an immobile barrier at 65MPH. The forces involved at that speed are far higher than those you see in crash test videos. The collapsible barrier would have helped, but not as much as dissipating the momentum over the distance that the OP's vehicle traveled. It seems pretty certain to me that in a clear condition direct crash the occupants would have fared much worse

Tesla's avoid most guardrails.
So do drivers.
 
#7 ·
Holy Sh*t! Amazing that you were both not hurt worse.

I wish I could help with your technology investigation, but the best I can do is say that I am glad that you & your son were OK and that you were smart enough to pick safe car (which hopefully can become safer if GM listens to you).
 
#16 ·
I'm happy both of you are ok. Wishing you both a quick recovery. What are you going to replace the Bolt with?
I'm sorry to say that I'm switching to a Tesla 3. I really loved my Bolt and 7 of 10 vehicles I have purchased have been Chevys, so they lost a pretty loyal customer.

I had initially intended to get the same exact Bolt, same color and options load out even. However, I just couldn't get over the fact that if we had a Tesla with AutoPilot on, we would not have had this accident. I was fairly pro-Tesla years ago; they even tried to recruit me to come work for them. Then all the quality problems and schedule problems came out, plus their deceptive website, of course their price is way too high, so I became pretty anti-Tesla.

Even though a long range rear with Autopilot is 12k more than a matching Bolt (in MN a loaded LT is still 35.5k and they won't come down more), the whole "not dead" angle overrides the price concern. My son is more valuable to me than the extra 12k. I also get another 105miles range, plus the ability to SuperCharge, but the decision really came down to AutoPilot.
I ordered last week, during the "cheap" autopilot phase and before the price increase, so I saved 4k compared to ordering today.
If there had been any other choice, I would have looked at that.
Lots of people are excited that we're getting a Tesla; I'm just not one of them because I didn't feel like there were other options.
 
#17 ·
I'm glad that both of you are (mostly) okay.

I definitely recommend escalating to GM corporate to have someone check out the vehicle. Given the conditions, I wonder if it's possible that certain sensors were frozen or disabled. Not that you would be able to verify this at this point, but is it possible that the airbag lights were on (indicting that they were not available)?
 
#19 ·
My son and I recently had an accident in the Bolt, . . . . However, I just couldn't get over the fact that if we had a Tesla with AutoPilot on, we would not have had this accident.
We're all grateful for affirmation of the Bolt's design saving you in a worst case situation. You have shared a great deal of detail about what happened after the crash, but an obvious omission of what caused the crash. One cannot but find a similarity to Tesla recently being sued for the AutoPilot hitting a guard rail and killing the driver. Tesla's defense is their warning the driver must always be aware and ready to assume control.

jack vines
 
#21 ·
My son and I recently had an accident in the Bolt, . . . . However, I just couldn't get over the fact that if we had a Tesla with AutoPilot on, we would not have had this accident.
We're all grateful for affirmation of the Bolt's design saving you in a worst case situation. You have shared a great deal of detail about what happened after the crash, but an obvious omission of what caused the crash. One cannot but find a similarity to Tesla recently being sued for the AutoPilot hitting a guard rail and killing the driver. Tesla's defense is their warning the driver must always be aware and ready to assume control.

jack vines
Yes, I'm also curious what happened leading up to the crash.
Also, IIRC, the Bolt's auto braking features only work up to ~50mph.
 
#20 ·
Pretty sure a Tesla would have been more aggressive about saving you if "autopilot" (they really need to dial back that name) had been on. But even so: did you have the "lane-keeping assist" option on the Bolt and was it enabled during this accident?

[Note to self: remember this next time I'm tempted to think modern A-pillars are "too thick." :) )
 
#26 ·
my Bolt's lane keep assist will actually steer the car back on the road if one crosses a line. once in awhile the car and I disagree where the line is, so I'm thankful it is just a gentle nudge. from your description, your Bolt only had the warning system? I thought the mirror light was only for car's in the lane next to you.
 
#27 ·
Wow, seeing as how there is snow, I do wonder if you hit ice. Because hitting a guard rail square on like you did short of getting distracted and taking your eyes off the road just seems kind of hard. Not sure any lane assist or even auto pilot can stop a jerk of the wheel.
 
#29 ·
I'm glad you're okay from this really traumatic event. It gives me more confidence to know I'll be ok if I ever wreck bad in my Bolt. Enjoy your Model 3, and be sure to post a review on how it compares to the Bolt!
 
#30 ·
Amazing story and I am very happy that you are here to write about it.


It's good to be thankful for all the things that went right (in this wrong night).



  • The snow covering the end of the W-guard rail ramped your Bolt over it and into the snow.
    • The guardrail uses a Trinity Soft Stop end terminal (LINK). It is a newer end terminal designed to extrude the guard rail under the car and thereby absorb energy. In your unfortunate accident, by missing the end terminal you were assured of a deceleration of less than 15Gs, which is the Federal MASH standard for highway guardrail.



  • Bringing an 1800 kg vehicle to a stop within the distances that were mentioned suggests a g-force on the order of 1.3, and a total time to zero velocity from 65 mph of ~2.6 seconds. I am sure your g-force was not uniformly applied, with wheels being ripped off and rolling the vehicle. The lower g-force may explain the lack of activation of the forward airbags. With proper cabin design, it is survivable.



  • Seat belts and all the other cabin design factors in your favor. Blunt force fractures require on the order of 100 Joules applied in a concentrated area. An 1800 kg vehicle at 65 mph (30 m/sec) has 810 kJoules of kinetic energy to get rid of. You and your son were well protected and probably received less than 0.1% of the energy in the collision. I do not think it was fun, but this level of protection would have been unimaginable 20 years ago. As you said, it's better to junk the car than mourn.




It's interesting to think about how autonomous systems could have prevented or mitigated the accident. If we look at a Google Map of the accident (no snow), we have the thumbnail attached. The end of the guard rail is approximately at the intersection of Stoppelman Road and US 169. This is an intersection with a ~400 foot right-turn bay. The vehicle would have had to depart the right-hand travel lane and travel in the right-turn bay, then continue off the road before striking the end terminal of the guard rail.



  • What level of lane following and control would be needed under dark conditions (with melting snow?) where the side stripe disappears for about 100 feet? Would the Tesla lane centering algorithm have worked in this case? The Bolt EV systems does not track well in these conditions from personal experience.



  • What level of vision system would have detected the end terminal or understood the terrain? Again, end terminals are small, and in the pictures were occluded with snow, dirt, and other visual 'debris'. Highway shoulders change drastically with snow. Darkness would complicate the solution.



  • Are any members aware of radar or lidar systems that would have brought a vehicle back into the lane once it was in the right-turn bay? Snow is a poor radar reflector and confuses 1.5micron lidar systems. The gentle slope of the mounded snow would also make radar/lidar returns difficult to differentiate. I feel existing systems could have made a correction, but then the vehicle would be driving on the shoulder because the right-hand turn lane ends.


A lot of stuff went right for you. Thankful that it did.
 

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