Triple-collision dummies for automotive safety testing

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The “triple-collision dummies” do not refer to a single standardized type, but rather to advanced crash test dummies such as safety mannequins or new female dummies. These dummies can simulate human skeletal/organ structures and are equipped with numerous sensors to collect detailed injury data. They overcome the limitations of traditional male models, covering diverse occupants (adults, children, different body types) and collision scenarios (frontal/side impacts), thereby enhancing vehicle safety. These models replicate human skeletal and organ structures while gathering detailed injury data through extensive sensors. Compared to basic male models, they accommodate diverse occupants (adults, children, various body types) and collision scenarios (frontal/side impacts), thereby optimizing vehicle safety design.

Application

The Mixed Type III Crash Test Dummy - Adult Male 50th Percentile is widely used in frontal collision tests to evaluate automotive safety restraint systems. We develop this Mixed Type III dummy and other dummy types in compliance with ECE specifications. Designed with human biomechanical motion in mind, it features movable joints at the thigh, lower leg, ankle, and foot. The dummy is also suitable for testing non-automotive products such as aviation, high-speed rail, wheelchairs, medical equipment, and sports gear.

Technical Parameters

1. Crash Test Dummy

Item	Description
Composition	Head, neck, torso (with/without skin), upper/lower trunk, thigh (left/right), lower leg (left/right, including foot), upper arm (left/right), lower arm (left/right, including hand)
Posture	Maintainable in seated or standing position
Anthropometry	Matches 50th percentile adult male for all segments
Standing Height	1750±10 mm (no sitting height data)
Sitting Height	883.9±5.1 mm
Mass Distribution & Total Mass	Matches 50th percentile adult male; total mass 77.65±1.18 kg
Material	Aluminum alloy head, steel neck and chest components; rubber neck/lumbar; chest with simulated skin
Sensor Provision	Pre-installed sensor locations and wiring space at all segments

2. Dummy Sensors

Item	Description
Source	Optional, Chinese/US manufactured
Compliance	Meets SAE J211/1 requirements
Cable Length	10 m signal cable per sensor
Certification	Each sensor must provide a calibration report/certificate from a third-party metrology institute
Responsibility	Responsible for sensor calibration and installation/commissioning on the dummy

3. Sensor Types & Quantity

Location	Sensor Type & Quantity
Head	3 × Accelerometers
Upper Neck	1 × 6-axis Force/Torque Sensor
Lower Neck	1 × 6-axis Force/Torque Sensor
Chest	3 × Accelerometers; 1 × Displacement Sensor
Lumbar	0 × 6-axis Force/Torque Sensor
Knee Joint	Optional
Ankle/Foot	Optional

4. Head & Chest Accelerometers

Parameter	Specification
Range	2000g
Sensitivity	0.15 mV/g
Excitation Voltage	2 ~ 10 VDC
Frequency Response	0 ~ 5 kHz (±1/2 dB)
Nonlinearity Error	±1% FS

5. Upper Neck 6-Axis Force/Torque Sensor

Parameter	Specification
Measurement Directions	Fx, Fy, Fz, Mx, My, Mz
Range	9 kN (Fx, Fy), 13 kN (Fz), 280 N·m (Mx, My, Mz)
Excitation Voltage	2 ~ 15 VDC
Nonlinearity Error	< 1%
Hysteresis Error	< 1%

6. Lower Neck 6-Axis Force/Torque Sensor

Parameter	Specification
Measurement Directions	Fx, Fy, Fz, Mx, My, Mz
Range	13.3 kN (Fx, Fy), 13.4 kN (Fz), 454.6 N·m (Mx), 455.3 N·m (My), 453.7 N·m (Mz)
Excitation Voltage	2.5 ~ 15 VDC
Nonlinearity Error	< 1%
Hysteresis Error	< 1%

7. Chest Displacement Sensor

Parameter	Specification
Range	≥ 75 mm
Sensitivity	1.0802 mV/mm
Supply Voltage	5 VDC
Hysteresis Error	< 1%
Nonlinearity Error	< 2%

8. Lumbar 6-Axis Force/Torque Sensor

Parameter	Specification
Measurement Directions	Fx, Fy, Fz, Mx, My, Mz
Range	15.08 kN (Fx), 15.08 kN (Fy), 20.1 kN (Fz), 602.7 N·m (Mx), 602.0 N·m (My)
Excitation Voltage	2.5 ~ 15 VDC
Nonlinearity Error	< 1%
Hysteresis Error	< 1%

Standards

EN standard (Euro-American sign)

GB standard (Chinese/Asian sign)

Features

The manikin's interior incorporates various metals, plastics, and rubber components, including a steel chest cavity, aluminum shoulder blades, plastic pelvic bones, and silicone skin. Additionally, numerous precision instruments such as accelerometers, potentiometers, and pressure sensors are installed throughout its structure to record the forces exerted on the manikin during collisions.

Head and Neck:

The skull and cranial vault are constructed as a single aluminum alloy unit, covered with either soft skin or hard synthetic resin. The neck combines rubber and aluminum alloy structures, with a central communication cable that simulates the dynamic structure, rotational flexibility, and extension feedback of the human neck.

Upper Torso:

The high-strength six-rib steel cage in the chest cavity incorporates flexible elastic material to simulate human chest rebound characteristics under external force. The ribs include anatomically correct left and right ribs, with the sternum and spinal column riveted to the back.

The sternum connects the front ribs to a sternum bending/rotation potentiometer. The angle between the neck and upper torso determines the cervical spine curve assembly, which integrates a 6-axis neck sensor. Two clavicles and clavicle connectors secure the entire scapula and shoulder girdle linkage.

Lower Torso:

A cylindrical rubber lumbar spine assembly enables sitting and standing like a real human. An optional lumbar transport unit secures it to the pelvis. The skin covering the pelvic periphery and buttocks is made of infused soft rubber/ Polyurethane soft and elastic skin is applied to the pelvis periphery and buttocks. Leg bones with optional spherical joints that limit movement mimic human leg characteristics, enabling free flexion, extension, and rotation. Thigh bones, lower leg bones, and ankle bones can be fitted with detection instruments to predict leg bone fractures and assess knee ligament conditions and injuries. Feet and ankles simulate heel and ankle joints to achieve movement.

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