We caught up with the Škoda factory's Crash Test Dummy crew whilst they were on their tea break.
Q: Aren't computer simulation tools now doing your job in the design office rather than in the lab?
A: No! certainly not! Computer simulation tools are playing an increasingly important role in the development of new cars, but crash test are still an essential part of the process. We work for Škoda in the crash test laboratory where 300 crash tests are carried out per year. The safety of cars in practice and under strictly defined conditions are all necessary for Euro NCAP rating and other standards.
Q: How many of you are there in the team?
A: There used to only be a few of us, but now that the tests are becoming more stringent and demanding, the number of crew has gone up to 12. There are 8 types of adult passenger dummies and then child dummies aged 18 months, 3, 6 and 10 years. We're quite the family now.
Q: Why are there so many of you?
A: Well, safety needs to be tested in many different situations and with different types of passengers. We have to represent male, female and child size humans. There are homologation regulations, consumer tests and manufacturer requirements based on population distribution. Each type of dummy reacts differently in a particular test and interacts differently with the vehicle restraint systems and designs. It's important to test as many options as possible to ensure that adult and child human passengers are as well protected as possible, wherever they sit in the car.
Q. Do you have to wear a uniform or special kit?
A. Yep. We're fitted with lots of sensors and measuring points. We're made from a wide range of materials that simulate the behaviour of human's bodies in specific situations. They use special metals to make our ribs, spine and joints, whilst our skin or pelvis is made of specific plastics.
Q. How does your work help with human safety?
A. The load on our body parts is measured, making it possible to deduce where and what actual injuries are likely to be. Vehicle design can then be adapted to improve vehicle safety.
Q. Are you expense to build?
A. Oh yes! Don't you know we are TOP QUALITY folk. Thor (the frontal dummy) costs 650,000 euros and WorldSID side impact dummy costs 350,000 euros. We're high maintenance dudes as well you know. Servicing and calibration costs a lot.
Q. Have things changed over the years?
A. Oh yes. Technology is constantly evolving. We are fitted with lots of sensors that measure acceleration, forces and deformation. For example, the male dummy used at the beginning of the year 2000 allowed measurements of 56 points on the body, the current version has 116 measurement locations. The EuroSID2 dummy with 57 measurement points was widely used for side impact testing, however it's being overtaken by the WorldSID dummy with 94 measuring points. WorldSID also has better similarity to the human body, rated at 7.6 out of 10, as opposed to 4.6 out of 10 for the older dummy.
Q. What does the future hold?
A. New types of dummies are being developed with greater human similarity and a greater number of sensors. Future models will try to simulate women with smaller frames and dummies that reflect the more advanced age of car occupants.
Q. Thanks for your time Crash Test Dummies
A. No problem, excuse us as we have to get back to work - it's a tough life, but we hope we are helping to save driver and passenger lives.
15/03/2023: Thanks to our colleagues at Škoda storyboard for this information.
