What is a Black Box? Meaning and Its Role in Air Crash

• On 12 June 2025, Air India Flight 171, a Boeing 787-8 Dreamliner, crashed immediately after takeoff from Ahmedabad Airport.
• The Aircraft Accident Investigation Bureau (AAIB) discovered the black box of the recent Air India crash in Ahmedabad to assist in identifying the cause.

• A black box is a unique recording machine installed in planes to investigate aircraft accidents and faults.
• Despite its different name, the black box is orange and has reflective tape. Its bright color makes it easy to locate after the plane has crashed.
• The black box was developed in 1954 by Australian scientist Dr. David Warren.

Components of a Black Box

A black box comprises two separate components. These parts work together to record important flight information and conversations between the pilots. Let’s understand what these parts are and how they help in air crash investigations.

1. Flight Data Recorder (FDR)

• Record significant flight data such as speed, height, engine functioning, and flight control operations.
• Stores data for the most recent 25+ hours of flight.

2. Cockpit Voice Recorder (CVR)

• Record voice from the cockpit, including pilot conversations, warnings, and background noises.
• Stores data for a minimum of 2 hours (new ones store 25 hours).
• Records radio contact with air traffic control and emergency calls.

Black boxes are constructed from durable materials such as steel or titanium. They are designed to withstand extreme temperatures.

• Can survive up to 1100°C for an hour.
• Survive impact forces of 3,400 times gravity.
• Function at deep-sea pressure for 30 days.
• Black boxes are installed at the rear end of planes because this area has the highest chances of surviving a crash.
• They are roughly as big as a shoe box and weigh around 5 kilograms.
• With an Underwater Locator Beacon (ULB) that broadcasts signals for 90 days in case of a water crash.

Limitations of Black Boxes

As we have understood, black boxes are extremely helpful in investigating air accidents, but some limitations can affect their performance and the recovery of data. Here are the major limitations you should know about:

• Power Failure: Black boxes may stop recording if the aircraft loses all electrical power.
• Physical Damage: Serious crashes can damage the devices, making it difficult or impossible to recover the data.
• Recording Gaps: Black boxes do not record certain times, as there are issues in the system.
• Limited Range: Underwater locator beacons have a limited range of approximately 3 nautical miles.
• No Video recording files, only audio and data.

With the growing need for better aviation safety, black box technology has seen many important upgrades. Here are some key improvements:

• More Storage Capacity: Modern black boxes can record up to 3,500 parameters, while the older ones can record only 100 details.
• Increased Recording Duration: CVRs can now record for up to 25 hours, from 30 minutes.
• Solid-State Memory: Using memory chips instead of magnetic tape diminishes the potential for damage.
• Artificial Intelligence Integration: Machine learning and artificial intelligence assist in analyzing the data and recognizing probable risks in real-time.
• Extended Battery Life: Underwater locator beacons are now available for 90 days instead of 30.

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India's aviation sector operates under a robust regulatory framework to ensure safety, transparency, and adherence to international norms.

• The Aircraft Accident Investigation Bureau (AAIB) investigates aviation accidents through black box data.
• The Directorate General of Civil Aviation (DGCA) is the regulatory body for flight recorder specifications.
• India follows the International Civil Aviation Organization (ICAO) regulations for black box technology.

Aircraft Accident Investigation Bureau (AAIB)

• The Aircraft Accident Investigation Bureau (AAIB) is an Indian special government agency that operates under the Ministry of Civil Aviation.
• The AAIB was set up on July 30, 2012, to make investigations autonomous from other aviation regulators.
• They test black boxes (flight data recorders), take statements from witnesses, review weather patterns, and disassemble aircraft wreckage.

Also read: Aero India 2025

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Black boxes are safety devices that make flying easier and safer for all of us. They are similar to silent witnesses that inform us what exactly occurred in airplane crashes. Although they are not perfect, they have solved a lot of aviation enigmas and avoided future plane crashes. 
With continuous advancements in technology, the black box is evolving into an even more powerful tool for ensuring aviation safety.

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