Các manơcanh thử nghiệm va chạm chịu hàng loạt đòn đánh có trang bị cảm biến để kỹ sư đo lường thương tích và nâng cao an toàn xe. Škoda thực hiện tới 300 bài kiểm tra mỗi năm và hiện dùng đội hình từ ít nhất mười hai manơcanh, bao gồm mẫu người lớn và trẻ em.
Các manơcanh hiện đại mang hàng chục đến hơn trăm cảm biến. Các bản cao cấp như THOR và WorldSID đắt đỏ, cần điều chỉnh định kỳ. Thiết kế mới phản ánh nhiều giới tính và độ tuổi để mở rộng đánh giá an toàn.
Phòng thí nghiệm va chạm của Škoda thực hiện các bài thử nghiêm ngặt, tái hiện hàng ngày. Hãng tiến hành tới 300 bài thử mỗi năm và sử dụng ít nhất 12 hình nộm, trong đó có tối đa 8 hình nộm người lớn, cùng các hình nộm trẻ em cho nhóm tuổi 1,5; 3; 6 và 10 tuổi.
Khung xác thử nghiệm kết hợp cấu trúc kim loại chắc chắn cho xương sườn, cột sống và khớp với vật liệu nhựa cho da và khung chậu. Các bộ phận có thể thay thế nên xác thử nền có thể tái sử dụng qua nhiều bài thử.
Phạm vi cảm biến đã được mở rộng: các mô hình Hybrid III cũ đo tại 56 điểm, trong khi các mẫu THOR hiện nay đo 116 điểm. EuroSID2 có 57 điểm; WorldSID cung cấp 94 điểm và giống người hơn. Các mô hình cao cấp rất đắt – chẳng hạn, mô hình THOR phía trước có thể giá khoảng 650.000 €, còn WorldSID khoảng 350.000 €.
Crash test dummies have a tough life. But their work saves lives. Find out who these dummies are and what they go through.
While computer simulation tools are playing an increasingly important role in the development of new cars, crash testing still has a place to be. That’s why Skoda has its own extensive crash lab, where it tests the safety of its cars in real-life, strictly defined conditions almost every day (up to 300 crash tests are carried out there every year).
Each dummy is equipped with dozens of sensors and measuring points. In addition to obstacles, lights, cameras and various sensors, crash test dummies are an essential element in car safety testing. And as crash tests become more and more stringent and rigorous, the number of crash dummies used by Skoda is also increasing. While in the past only a few dummies were needed, today the Czech carmaker uses at least twelve. There are up to eight adult passenger dummies. And then there are the child dummies, representing children aged 1.5, 3, 6 and 10.
Jan Domkář, vehicle safety development coordinator, explains.
The size and design of the dummy is based on the requirements of individual homologation regulations, consumer testing and internal requirements based on population distribution. And the response varies depending on the design and safety systems of the vehicle. With the aim of testing as many cases as possible to ensure that both adult and child passengers are well protected, no matter where they are seated in the vehicle.
50% male, 5% female
In addition, each type of test uses a different dummy shape. They are specially designed to best simulate human body behaviour for a specific test. Domkář explains: “For frontal impacts, dummies such as Hybrid III or Thor are used, while for side impacts, we use EuroSID II and WorldSID dummies.”
Inflatable dummies are also used in automotive development testing. As Jan Domkář explains, only standardized dummies are used in the assessments. This is based on the requirements of homologation tests and the more rigorous consumer tests performed according to methods such as EuroNCAP. The same dummies are used in both official and internal tests conducted by the company to verify safety during vehicle development before being confirmed by official testing.
Metal ribs and spine wrapped with a plastic skin
Crash test dummies are always made from a variety of materials. The basic structure is solid and durable metal, but the dummy’s body is also made of materials that simulate human body behaviour in specific situations as realistically as possible. Special metals are used for the ribs, spine or joints, while the dummy’s skin or pelvis is made from plastic. The loads acting on these parts are measured, allowing the position and severity of potential injuries to be inferred. Of course, individual parts can be replaced, so the basic dummy is reusable and effectively has an unlimited lifespan.
There are eight types of adult dummies used by Skoda. Many design elements of the crash dummies are patented, and only a few manufacturers worldwide produce dummies of the highest standard. Consequently, these dummies are expensive – in fact, they are often the most costly equipment used in crash testing. “For example, the front dummy Thor costs 650,000 euros and the WorldSID side impact dummy costs 350,000 euros. In addition, you must factor in the considerable costs of maintenance and calibration,” Domkář explains. Calibration is also carried out after a certain number of specified tests or when the biomechanical limits are exceeded.
Technology is constantly evolving
Each dummy is then fitted with dozens of sensors measuring acceleration, force and deformation. Moreover, this entire technology is constantly evolving. While the 50% male dummy (Hybrid III) used at the turn of the millennium allowed measurements at 56 points on the body, the current THOR dummy has 116 measurement points. Similarly, the EuroSID2 dummy with 57 measuring points was once widely used for side impact testing, but today it has been largely replaced by the WorldSID dummy with 94 measurement points. WorldSID also offers significantly better similarity to the human body, rated at 7.6/10 compared to 4.6/10 for the older dummy.
Modern cars put into testing today are becoming increasingly complex. In addition to greater human resemblance and a greater number of sensors, new types of dummies are appearing in tests from time to time. “Work is currently underway on the Thor and WorldSID dummies, which will represent 5% women. Another trend in dummies is towards reflecting the older age range of car occupants,” Domkář said, pointing to where innovations in this area can be expected.