A crash test dummy, or simply a dummie, is a full-scale anthropomorphic test device (ATD) that simulates the dimensions, weight proportions, and joints of the human body during a traffic collision. Researchers, automobile, and aircraft manufacturers use dummies to predict the injuries a person might suffer in a car accident. Modern dummies are typically used to record data such as impact velocity, crush force, body bending, folding, or torque, and deceleration rate during a collision.
Before the development of crash test dummies, automotive companies used human cadavers, animals, and live volunteers for testing. Cadaveric bodies have been used to modify various vehicle components, such as seatbelts. This type of testing may provide more realistic results than using dummies, but it raises ethical dilemmas because human cadavers and animals cannot consent to research. Today, animal testing is less common. Computational models of the human body are increasingly used in industry and research to supplement the use of dummies as virtual tools.
The side impact test dummy is one of the most bio-fidelity dummies currently available for side impact research, accurately representing the biomimetic characteristics of an adult male at the 50th percentile. Its design and manufacture are based on ISO standards. Equipped with a modular measurement system, sensors, and a complete DTI integrated data acquisition solution (up to 144 channels), the vehicle crash safety standard is a crucial component of my country's passive safety standards system. Crash safety technology is a crucial lifeline and safety barrier for drivers and passengers. The development and innovation of crash testing technology is key to advancing crash safety technology. With in-depth research on road traffic accidents and the rapid adoption of new energy electric vehicles, crash safety testing has expanded from head-on, side, and rear-end collisions to include pole collisions, head-on collisions, rollovers, side pole collisions, electrical safety measurements, and battery pack support tests. Evaluation criteria have also expanded from protecting occupants to encompassing all personnel and objects inside and outside the vehicle.
According to statistics, deaths caused by pole collisions account for as much as 38% of all vehicle accident fatalities. This is because pole collisions avoid the high-strength B-pillar, resulting in a smaller impact area and greater risk of severe deformation and even laceration. Pole impact testing of electric vehicles is rare in China, and the use of side impact test dummies is undoubtedly a significant breakthrough.
TÜV SÜD's Active Side Impact Simulator is a unique, advanced technology for non-destructive, physically-based simulation of side impacts with active, controlled deformation of the vehicle's side structure. It's not only one of the few such systems in Europe, but also the first to incorporate simultaneous front and rear seat load testing.
An integral part of vehicle development projects using ALIS is finite element analysis support. Virtual simulations of sled tests provide comprehensive insights into system setup issues and maximize testing efficiency.
There are two approaches to crash testing: the casual observer and the professional. While we can assess a vehicle's safety based on body deformation and door component detachment, professional safety engineers go beyond that. Imagine someone who falls and appears fine, only to suffer a stroke later in the day. Therefore, assessing the occupant's physical condition after a collision is crucial.
Some believe that the purpose of a crash dummy is to determine whether its limbs deform or break after a collision, while also using the "red powder" on its surface to easily identify surface scratches or damage caused by impact. To this end, professional crash dummies are equipped with force sensors and accelerometers. For example, the accelerometer mounted on the head can measure the intensity of the head's vibrations during a collision. This provides scientific data support for injury assessments and better reflects real-world conditions. In addition to the numerous sensors installed on crash dummies, their construction is also meticulously crafted. If you've ever handled a clothing mannequin, you'll notice its plastic texture and its significantly lighter weight than a real person.
Why is it so much lighter? While dummies in the clothing industry only need to maintain their shape, crash dummies are different. The human body is highly flexible, and in a collision, multiple organs can become dislocated or move with varying degrees of force. Therefore, the dummies must not only match a real person's weight but also distribute the weight like a human to ensure accurate assessment of the damage to each organ. For example, the head of an adult crash dummy must be set at 4.5 kg to accurately assess how quickly the head will impact the inflating airbag. For this reason, a dummy like the WorldSID 50th has as many as 400 parts, including the head, neck, chest, upper limbs, hips, lower limbs, feet, and various connecting mechanisms, making it a truly sophisticated instrument.
Through the above introduction, you've learned that a crash dummy is a sophisticated instrument. Just as delicious fish bones require a skilled chef to bring out their best flavor, the same is true for crash dummies; how to effectively utilize them is crucial.
For this reason, the proper placement of a crash dummy during a crash test is a complex matter. The following two aspects are crucial:
Before a crash test, test engineers use instruments to place a calibrated dummy into the corresponding seat of the test vehicle and adjust the dummy's position and seating position according to test standards.
Some may ask, is there a specific seating position? Of course there is. The seating position of a crash dummy is determined based on reasonable seating positions and is the result of extensive scientific research and statistical analysis. After all, the purpose of a crash test is to simulate the vast majority of situations, ensuring that the test results are universally applicable.
While vehicle safety testing can demonstrate a vehicle's safety, personal safety awareness is equally important. For example, some people like to sit back while driving, while others prefer to sit with their backrests tilted very straight. These unsuitable sitting positions clearly compromise the vehicle's overall safety.
For a long time since the first automobile crash tests were conducted in the 1970s, data acquisition systems have been large and cumbersome. The only way to obtain data was through cumbersome and lengthy wiring cables between the sensors within the dummy and the data acquisition system. However, the intensity of a car crash inevitably creates the risk of data loss.
Today, data acquisition systems have significantly improved in both size and functionality, enabling crash test data acquisition from offline to integrated within the dummy. This eliminates the need to worry about sensor data loss or errors caused by a violent collision, ensuring highly accurate test results.
From the birth and development of crash test dummies, to their unique role in side impact testing, and to their sophisticated structure and scientific operation, we have demonstrated the irreplaceable importance of this full-scale, anthropomorphic testing equipment in the automotive safety field. It is not only a key tool for researchers to predict injuries and improve vehicle safety performance, but also a core force driving the continuous advancement of automotive crash safety technology. With the continuous innovation of technology, crash test dummies will become more accurate and intelligent, building a more solid line of defense for our travel safety.
