EN
search-icon
logo
EN
search-icon
ZF_Lifetec_dummy_laboratory_2_1_2048px.jpg

Behind the Scenes: Look into the Dummy Laboratory

Products & Technology

HomeTechnologyStoriesBehind the Scenes: Look into the Dummy Laboratory

Convincing test experience

When it comes to global occupant safety systems such as airbags and seatbelts, ZF is the leader, as is widely known. What is not quite so commonly known is that crash tests actually take place here all the time – 24 hours a day, 7 days a week. ZF is among approximately 100 companies worldwide that regularly perform component-level tests with crash test dummies (anthropomorphic test devices, or ATD).

This expertise is based in the Passive Safety Systems division in Alfdorf, Germany. The location has dealt with safety issues since the 1970s. Back then, executive managers and other volunteers sometimes even served as live crash test dummies. Although this was admittedly an impressive way of convincing customers of the effectiveness and quality of safety solutions, it is no longer practiced today for good reasons.

In any case, the former Repa GmbH (a fine-blanking and refurbishment plant), the German specialist for seatbelts and later also airbags, set up a new, second plant in Alfdorf at that time. The capital for this was provided through a 70 percent stake held by the US Group TRW. And this was acquired by ZF in 2015.

To enlarge the pictures, please click on one of them.

Historisches_Foto_Bild1_3_2_748px.jpg

Historisches_Foto_Bild2_3_2_748px.jpg

Historisches_Foto_Bild3_3_2_748px.jpg

Historisches_Foto4_3_2_748px.jpg

Historisches5_Foto5_3_2_748px.jpg

Dummy_Familie_1_1_422px.jpg

Enhanced safety thanks to 7,000 dummy crashes

Now let us come back to ZF crash tests as they are conducted today. Four Group locations, each with a different number of sled installations, carry out these tests: Detroit in the USA, Shanghai in China, Yokohama in Japan, and Alfdorf in Germany. Their objectives? To examine the numerous load cases from which the (regional) NCAP assessment for occupant safety is derived. And, of course, to continue to improve airbags and seatbelts for the purpose of road safety; and to help bring innovations to production maturity. A total of 120 ATDs are in active use at ZF. Each one completes up to 70 tests per year – in other words, ZF causes about 7,000 crashes in its installations every year. The oldest “working” crash test dummy, now 31 years old, has already been involved in around 2,200 accidents.
Innenleben_Dummy_1_1_422px.jpg

Preparing, checking, and repairing ATDs

Without the ZF dummy laboratory in Alfdorf, that dummy would have been disabled long ago: The team here – just like our colleagues at the other locations – is responsible for keeping the dummies, which cost up to EUR 1 million, in working shape for as long as possible. It checks the ATDs for mechanical functionality after they have been used in approximately ten tests. They are also inspected if the loads from different tests have added up to a certain limit value. Up to 200 sensors, and even more measuring channels, of a dummy must also be checked. After all, they must correctly record the accelerations and force effects during crash tests. The laboratory also functions as a kind of “trauma surgery”: the team replaces body parts of the dummies if they have been broken due to (excessively) high loads. It prepares the ATDs specifically for each test, programming and calibrating the sensor system.

Seated safety

Like myself, most laboratory experts are trained electrical engineering technicians, because the job requires them to handle sensors and data with confidence. Whatever qualifications are required beyond that are based on interest and experience. Of course, there is training, such as the one that had to be done recently for the latest, particularly human-like (biofidelic) and complex THOR dummies. The test requirements themselves are also currently changing. The trend toward fully automated driving and electric cars with a level floor raises hopes for many new seating positions and settings. But each and every one of them must be tested in terms of occupant stress and safety before they can be implemented in a series-production vehicle. This diversity can only be covered by virtual crash simulations on a computer. Nevertheless, the ATDs in the ZF laboratories need not fear the future: the data on which these simulations are based can be obtained only through crash tests involving actual dummies.

Turza_Sven_magazine_author.jpg

Sven Turza is team leader of the ZF dummy laboratory in Alfdorf.

Next Stories

ZF_Lifetec_crash-clan_Bild_2_1_2048px.jpg

The “Crash Clan” Protects Us

How dare we call them “dummies”! They are actually a family of intelligent specialists who make an enormous contribution to occupant safety. It’s time to get to know them better.

Read more
ZF_Lifetec_Freisler_und_Kollege_web_2_1_2048px.jpg

Meeting the Challenge of Knee Airbags

One of the most exciting parts of the automotive industry is the idea that there is always a way to make something lighter, smaller, safer.

Read more
Go Back
logo

ZF Airbag Germany GmbH 

Wernher-von-Braun-Straße 1

84544 Aschau am Inn



T: +49 8638 9650

Follow Us
cib_linkedin_77edf4ea2b.pngic_baseline_facebook_5b9a665cd5.pngmdi_youtube.svg
© ZF LIFETEC

Data Privacy

logo

Essential

Essential cookies enable basic functions and are necessary for the website to function properly.

Statistics

Statistics cookies collect information anonymously. This information helps us understand how our visitors use our website.