An Automotive HVAC Manikin is a specialized thermal manikin designed for evaluating thermal comfort inside vehicle cabins. It simulates human heat exchange, sweating behavior, and physiological responses under various environmental conditions. Modern automotive brands rely on HVAC manikins to develop more comfortable, energy-efficient, and user-centered climate control systems.
An Automotive HVAC Manikin is a full-body or partial-body thermal manikin embedded with:
Multiple heat flux sensors
Surface temperature measurement zones
Segmented heating control systems
Optional sweating modules (evaporative models)
Integrated data acquisition systems
It replicates how a human body exchanges heat with the automobile environment, allowing engineers to quantify thermal comfort inside cars, trucks, buses, or aircraft.
Unlike standard thermal manikins used for clothing testing, HVAC manikins are optimized for seat interaction, airflow distribution, solar load effects, and localized air-conditioning outlets in vehicle cabins.
Vehicle Cabin Climate Control Development
Automotive HVAC manikins help engineers optimize:
Air-conditioning outlet locations
Vent airflow speed and direction
Temperature distribution
Defrosting and demisting efficiency
Air-mixing strategies
By measuring local skin temperatures and heat flux, engineers can identify uncomfortable areas (hot spots, cold spots) and improve cabin climate uniformity.
Seat Ventilation and Heating System Evaluation
Seats are a critical comfort component. HVAC manikins are used to assess:
Seat heating response time
Ventilated seat airflow effectiveness
Thermal comfort at seat–body interface
Moisture removal capability in hot conditions
This is especially important for premium vehicles and EV platforms where comfort is tied to brand differentiation.
Energy Efficiency Optimization for EVs (Electric Vehicles)
EVs rely heavily on HVAC efficiency due to limited battery capacity.
Manikin-based testing helps evaluate:
Low-energy HVAC modes
Localized microclimate control
Heat pump performance under cold conditions
Personalized comfort solutions (zonal HVAC, smart vents)
The goal is to maintain thermal comfort while minimizing energy consumption.
Solar Load and Environmental Condition Simulation
Climate chambers or solar simulation labs use HVAC manikins to evaluate:
Cabin heating under high solar radiation
Cooling system response under extreme heat
Window insulation and glazing performance
Ambient humidity and airflow impact
Automotive brands use this data to design climate systems suitable for global markets—deserts, tropics, winter regions.
Thermal Comfort Grading & Interior Material Evaluation
HVAC manikins measure user comfort with different interior materials:
Leather vs. fabric seats
Synthetic upholstery
Seat cushion foam properties
Dashboard materials under solar exposure
This helps manufacturers choose materials that balance comfort, cost, and sustainability.
Thermal Indicators
Heat loss rate
Skin surface temperature
Local heat flux
Equivalent temperature (Teq)
Thermal asymmetry
Moisture & Evaporative Indicators (Sweating Models)
Evaporative cooling rate
Moisture accumulation
Microclimate humidity between manikin and seat
Drying time of seat materials
Comfort Metrics
Overall thermal comfort score
Local discomfort mapping
Predictive comfort models (PMV/SET*)
Auto-industry comfort indices
These metrics are essential for engineering vehicle cabins that feel comfortable for drivers and passengers across various climates.
High Repeatability and Control
Environmental conditions, airflow, and temperature can be precisely controlled—far more reliable than human subject tests.
Safe Evaluation Under Extreme Climates
Manikins can withstand heat, cold, humidity, and solar radiation levels unsafe for humans.
Objective, Quantifiable Data
Provides measurable values for comfort performance instead of subjective human feedback.
Faster R&D Cycles
HVAC designs can be iterated quickly without human fatigue or variability.
Supports Energy-Efficient Climate Solutions
Critical for EVs and vehicles aiming for optimized HVAC load.
Cannot Fully Simulate Human Behavior
Movements, posture changes, metabolism variation, and psychological comfort are not fully replicated.
Limited Sweat Accuracy (for some models)
Only sweating manikins provide moisture data; dry models may not reflect real perspiration patterns.
High Cost & Technical Complexity
Acquisition, calibration, climate chamber operation, and maintenance are expensive.
Requires Skilled Operators
Data interpretation requires expertise in thermal comfort research and automotive testing.
Automotive HVAC manikins support several relevant standards:
ISO 14505-2 — Evaluation of vehicle thermal environments using thermal manikins
SAE J2234 — Vehicle climate control evaluation
ISO 7730 (related) — Thermal comfort (PMV/PPD)
ASHRAE 55 (reference) — Indoor comfort evaluation
Manufacturers often use industry-specific testing procedures developed by OEMs and Tier-1 suppliers.
Ideal users include：
Automotive manufacturers (passenger cars, EVs, trucks, buses)
Interior system suppliers (Tier-1/Tier-2)
Seat manufacturers
Climate system and HVAC suppliers
Aerospace climate control developers
Independent climate labs and research institutions
These manikins help achieve precise climate engineering, reduced energy consumption, and enhanced occupant comfort.
Automotive HVAC Manikins have become a core technology in modern vehicle engineering. With their ability to simulate real human thermal responses, they enable manufacturers to design more comfortable, energy-efficient, and climate-adaptive vehicles.
From seat heating to airflow optimization, and from EV energy-saving strategies to global comfort validation, HVAC manikins deliver scientifically validated insights that are critical for future automotive innovation.
