Water-filled dummy

The Water-filled Dummy (Ballast Weight Dummy) is a highly practical simulation tool designed to replicate human occupant mass in vehicle testing environments. Constructed from high-strength, impact-resistant Polyethylene (PE), this dummy features a hollow-core design that allows you to adjust its total weight by filling it with water, sand, or high-density metallic grit. Its specialized form factor is optimized for secure fastening with standard automotive seatbelts, providing you with a stable and repeatable ballast solution for vehicle dynamics, suspension tuning, and safety system verification.

Applications

Water-filled 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

1.Seatbelt Compatibility: The anatomical curvature and structural rigidity allow you to bind the dummy securely using standard 3-point or 5-point vehicle seatbelts without slippage.

2.Adjustable Mass Management: You have the flexibility to use water for standard occupant weights or high-density solids like iron sand to simulate "overweight" scenarios or cargo loads.

3.Optimized Center of Gravity: The 240mm base height and internal volume distribution ensure the center of gravity (CoG) remains consistent with a seated human, providing realistic vehicle dynamics.

4.Industrial-Grade Durability: The high-strength PE shell is designed to resist cracking, UV exposure, and impact, ensuring long-term use in both laboratory and outdoor track environments.

5.Large Diameter Inlet: The 86mm opening allows you to fill or drain the dummy quickly, significantly reducing setup time between test cycles.

6.Highly Customizable: The system supports the integration of internal sensors or external lifting straps and rings to suit your specific laboratory workflow.

Parameters

1. 75kg Class Weight Dummy

2. 85kg & 90kg Class Weight Dummy

Accessories

Compatible with sandbags in the following weights: 1kg, 3kg, 5kg, 7kg, 10kg, 15kg, 20kg, 30kg, 40kg, 50kg              

Test Procedures

1.Selection: Choose the appropriate dummy class (75kg or 85/90kg) based on the occupant profile required by your test standard.

2.Filling: Place the dummy on a scale. Use the 86mm inlet to fill it with water (for standard weight) or solids (for higher weight) until you reach the target mass.

3.Positioning: Place the dummy centrally in the vehicle seat. Ensure the base is flush against the seat back to maintain the correct CoG.

4.Binding: Pull the vehicle seatbelt across the dummy and click it into the buckle. Tighten the belt to ensure the dummy remains stationary during acceleration or braking.

5.Verification: Check that the dummy does not interfere with steering or other cabin controls if placed in the front seats.

6.Drainage: After testing is complete, drain the liquid to return the dummy to its lightweight state for easy storage.

FAQ

1. Can I use the 75kg dummy to simulate a 100kg passenger?

Yes. By filling the 70L shell with a denser material such as sand or iron grit instead of water, you can achieve a total weight of up to 120kg, allowing you to simulate heavier occupants using a smaller shell.

2. Is the dummy's material safe for use with anti-freeze?

Absolutely. The high-strength PE material is chemically resistant. If you are conducting winter track tests, you can add glycol-based anti-freeze to the water without damaging the internal walls of the dummy.

3. Will the dummy slide around during high-speed cornering?

When properly bound with a vehicle seatbelt and placed on a standard seat fabric, the friction and belt tension keep the dummy stable. For extreme lateral G-force testing, we recommend using the version with integrated lifting straps to provide extra anchoring points.

4. How do the sandbags interact with the dummy?

The sandbags (available from 1kg to 50kg) are used as external "trim weights." If your test requires a very specific mass (e.g., exactly 77.5kg), you can fill the dummy to 75kg and secure a 2.5kg sandbag to the dummy or the footwell.

5. Does the dummy have an internal baffle to stop water sloshing?

The internal design is optimized to minimize the "free surface effect." However, for ultra-precise dynamics testing where fluid movement must be eliminated, we recommend filling the dummy with a combination of water and foam or switching to a solid fill like sand.