The development of new technologies, from early aviation to modern artificial intelligence, has consistently presented unforeseen challenges, necessitating the crucial work of test engineers. These unsung professionals are responsible for identifying and mitigating risks, ensuring that innovations do not pose undue dangers to the public.
Alex Davies' book, "How To Keep A Plane In The Sky," delves into the often "wild" and "unseen" world of test engineering. The subtitle reflects the obscure nature of this field, which is far from for the faint of heart. The necessity of rigorous testing became starkly apparent in aviation safety. For example, a 1960 incident where 62 people died after their plane was struck by starlings prompted the Federal Aviation Administration to mandate tests involving firing dead chickens at airplane propellers. This ensures propeller designs can withstand avian impacts, a gruesome but effective method.
Beyond aviation, test engineering addresses a myriad of operational and non-operational risks. Operational risks involve external factors that can cause harm even when a device functions as intended. An example is the danger posed by circular table saws, which, due to careless use, cause numerous finger injuries daily in the United States. The SawStop device, which halts the blade upon contact with skin, mitigates this risk by completing an electrical circuit, triggering a mechanism that jams the wheel. While effective, its cost limits widespread adoption.
Non-operational risks arise from device malfunctions or wear and tear. Colonel John Stapp's pioneering work in the late 1940s exemplifies testing for such risks. Stapp volunteered for experiments to determine the limits of human deceleration. Strapped into a sled on a linear decelerator, he was subjected to extreme speeds followed by violent braking. Despite breaking wrists and losing dental fillings during tests, Stapp ultimately endured 40g's of force, far exceeding previous limits. These tests, while hazardous, provided vital data on human tolerance to deceleration.
The book also highlights less dramatic, yet equally important, safety innovations. The magnetic closures on refrigerators, for instance, replaced external latches that posed a suffocation risk to children who might hide inside. Similarly, child-resistant lids on medicine bottles are intentionally designed to be only about 85% child-proof. This allows adults to open them while still preventing most children from accessing potentially harmful substances. Since the introduction of these safety lids, accidental child poisonings have decreased significantly.
Davies' work suggests that while the field of test engineering may not always be compelling, it is undeniably conscientious. The book explores the historical context of safety innovations, such as Elisha Otis's demonstration of his elevator safety brake in 1854. It underscores that with each new technological advancement, a new set of safety considerations emerges. The rise of AI represents the latest frontier, where test engineers will continue their vital role in ensuring that progress does not come at the cost of public safety.