Split-Body Counterweight Dummy – Hollow
Category：Manikin System
Introduction
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.
Parameters
1. 100kg Class Weight Dummy
| Item | Specification |
|---|---|
| External Dimensions | L508 × W494 × H846mm |
| Standard Volume | 100L |
| Material | High-strength PE |
| Left-Right Width | 494mm |
| Front-Rear Width | 508mm |
| Center of Gravity Height | 295mm |
| Base Height | 275mm |
| Total Height | 860mm |
| Water Inlet Diameter | 95mm |
| Application | Automobile, locomotive, high-speed rail, or space simulation |
| Ballast (Liquid) | Liquid (water), total weight 100–110kg after filling |
| Ballast (Solid) | Solid (sand/pebbles/glass beads/iron sand), total weight 150–220kg |
| Customization | Customizable color, shape, size, lifting straps, lifting rings, sensors, etc. |
2. 85kg Class Weight Dummy
| Item | Specification |
|---|---|
| External Dimensions | L620 × W400 × H620mm |
| Standard Volume | 80L ~ 90L |
| Material | High-strength PE |
| Left-Right Width | 400mm |
| Front-Rear Width | 620mm |
| Center of Gravity Height | 240mm |
| Base Height | 240mm |
| Total Height | 700mm |
| Water Inlet Diameter | 86mm |
| Application | Automobile, locomotive, high-speed rail, or space simulation |
| Ballast (Liquid) | Liquid (water), total weight 85–95kg after filling |
| Ballast (Solid) | Solid (sand/pebbles/glass beads/iron sand), total weight 120–160kg |
| Customization | Customizable color, shape, size, lifting straps, lifting rings, sensors, etc. |
3. 75kg Class Weight Dummy
| Item | Specification |
|---|---|
| External Dimensions | L520 × W400 × H690mm |
| Standard Volume | 70L |
| Material | High-strength PE |
| Left-Right Width | 400mm |
| Front-Rear Width | 520mm |
| Center of Gravity Height | 240mm |
| Base Height | 240mm |
| Total Height | 730mm |
| Water Inlet Diameter | 86mm |
| Application | Automobile, locomotive, high-speed rail, or space simulation |
| Ballast (Liquid) | Liquid (water), total weight 75kg after filling |
| Ballast (Solid) | Solid (sand/pebbles/glass beads/iron sand), total weight 140kg |
| Customization | Customizable color, shape, size, lifting straps, lifting rings, sensors, etc. |
4. 65kg Class Weight Dummy
| Item | Specification |
|---|---|
| External Dimensions | L480 × W400 × H600mm |
| Standard Volume | 60L |
| Material | High-strength PE |
| Left-Right Width | 400mm |
| Front-Rear Width | 480mm |
| Center of Gravity Height | 380mm |
| Base Height | 155mm |
| Total Height | 730mm |
| Water Inlet Diameter | 86mm |
| Application | Automobile, locomotive, high-speed rail, or space simulation |
| Ballast (Liquid) | Liquid (water), total weight 65kg after filling |
| Ballast (Solid) | Solid (sand/pebbles/glass beads/iron sand), total weight 120kg |
| Customization | Customizable color, shape, size, lifting straps, lifting rings, sensors, etc. |
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
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.
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.
