Split-Body Counterweight Dummy - Hollow

The Split-Type Ballast Weight Dummy is a highly versatile weight simulation tool designed to replicate occupant mass in automotive and transit testing. By utilizing a high-strength PE hollow shell that you can fill with water, sand, or iron grit, the dummy provides an adjustable and cost-effective solution for vehicle dynamics, braking, and suspension testing. Its split-type design ensures ease of handling and precise placement within various seat configurations. Whether you need a standard 75kg occupant simulation or a heavy-duty 220kg load, this ballast system allows you to achieve accurate center-of-gravity (CoG) height and mass distribution required for professional engineering evaluations.

Applications

Split-Body Counterweight Dummies are widely used by automotive manufacturers both domestically and internationally.

Standards

Toyota, Honda, Nissan; Mercedes-Benz, BMW, Volkswagen; General Motors, Ford; Hyundai, Kia; as well as automakers from India, Pakistan, Europe, South Africa, the Middle East, and domestic Chinese manufacturers including SAIC, FAW, BAIC, Volkswagen, King Long, Yutong, JAC, Geely, BYD, Haima, and others.

Features

Classified by external dimensions and capacity:

700×620×400mm (80L), 690×520×400mm (70L), 730×480×400mm (60L), 508×494×846mm (100L)

By payload capacity:

60kg, 65kg; 68kg, 70kg, 75kg; 80kg, 85kg, 90kg, 95kg; 100kg, 110kg

Parameters

1. 100kg Class Weight Dummy

2. 85kg Class Weight Dummy

3. 75kg Class Weight Dummy

4. 65kg Class Weight Dummy

Accessories

(1) Sealing Caps: High-pressure screw caps for the 86mm/95mm inlets.

(2) Lifting Straps/Rings: For mechanical handling and securing.

(3) Solid Fill Funnel: Designed for rapid sand or iron grit loading.

(4) Integrated Sensors: Optional load cells or accelerometers (custom order).

(5) Anti-Freeze Additive Kit: For use in cold-weather testing.

Test Procedures

1.Selection: Choose the dummy class (65kg–100kg) based on your specific test protocol and seat dimensions.

2.Filling: Place the dummy near the vehicle. Unscrew the inlet cap and fill with the required medium (Water for standard, Iron Grit for max load) until the target mass is reached on a scale.

3.Installation: Secure the dummy into the vehicle seat. Ensure it is positioned flush against the seat back to maintain the correct center of gravity.

4.Securing: Use the vehicle’s seatbelt or additional ratchet straps to prevent the dummy from shifting during dynamic maneuvers.

5.Execution: Perform the driving or static test as per your engineering requirements.

6.Drainage: After testing, if using water, open the drain/inlet to empty the shell for lightweight transport and storage.

FAQ

1. Can I mix water and sand to achieve a specific weight?

It is generally not recommended. Mixing solids and liquids can create a "slurry" that is difficult to drain and may shift unevenly during dynamic tests. It is best to use either pure liquid or pure dry solids.

2. Is the dummy's shape compatible with sports seats with high bolsters?

Yes, the various width options (400mm to 494mm) are designed to fit the majority of global automotive seats. For very narrow racing buckets, the 65kg or 70L models are usually the most compatible.

3. How do I calibrate the weight of the dummy?

You should weigh the empty dummy first, then fill it while it sits on a calibrated industrial scale. Because the PE shell has a standard volume, you can accurately calculate the required density of the fill material (e.g., iron sand vs. regular sand) to hit your target weight.

4. What is the maximum weight I can achieve with iron grit in the 100L model?

Because iron grit has a much higher density than water ($1000 kg/m^3$), the 100L model can theoretically reach over 220kg when filled with high-density metallic solids, provided the structural limits of the PE shell are respected during handling.

5. Are these dummies suitable for roof rack load testing?

While designed for seats, their flat-bottomed nature allows them to be used for cargo and roof rack ballast, provided they are securely strapped down using the optional lifting/securing rings to prevent sliding.