Kistler and Cellbond unveil new crash test dummy with measuring chain

“Cellbond and Kistler have now created a new-generation THOR (Test Device for Human Occupant Restraint) based on drawings published in 2019 by the National Highway Traffic Safety Association (NHTSA) in the USA.”

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Kistler and Cellbond launch its new crash test dummy, with a complete measuring chain. The THOR (Test Human for Human Occupant Restraint) 5F ATD corresponds with the fifth percentile of the adult population, with just 5% of adults being either smaller or lighter than the dummy. The model is also made up of 250 separate components due to the clavicle, pelvis, and neck design, to make the dummy closely resemble the human anatomy. 

Key information:

  • Kistler and Cellbond have unveiled its new crash test dummy.
  • Containing a complete measuring chain, developers claim the new model should provide a more realistic simulation of frontal impacts.
  • The THOR 5F has already received the recommendation for implementation by the independent European New Car Assessment Programme (Euro NCAP).

Kistler and Cellbond created the new model based on drawings published by the US National Highway Traffic Safety Association (NHTSA) in 2019. According to the developers, the THOR 5F allows for a more realistic simulation of frontal impacts, especially relating to female occupants, who tend to be smaller and lighter than average people. The new model is the successor to the Hybrid III 5th Percentile ATD. The THOR 5F has received recommendation for implementation for future crash tests (presumably from 2029) by the independent European New Car Assessment Programme (Euro NCAP).

Cellbond initially started the project in September 2021 and was joined by Kistler in January 2022. While Cellbond started the design, Kistler took over the development of the ribs and rib stiffeners, which the company had previously supplied for the THOR 50M model. The 50M compromised of 750 parts while the 5F contains only 250 components. Which naturally results in a simpler production and assembly process.

During frontal crash tests, loads are assessed by up to 160 measurement axes within the test dummy. Kistler developed an inertial measurement unit (IMU) for the THOR 5F model that is mounted in its head, chest, pelvis, and feet. These areas were selected as they are the prime locations where the body absorbs the initial impact. IMUs measure three acceleration and three rotation rates in small spaces, sensor signals are then converted from analogue to digital measurement data in the sensor.

Kistler also developed a DTI recorder with 288 channels that connect to the dummy’s 160 measurement axes. The DiMod 1.6 is based on the THOR 50M recorder with storage and battery units that are connected by a single cable. During a crash test, if the connection to the onboard measuring system is lost, then the recorder will continue to log reliable measurement data. Developers also promote that this allows for the standalone use of the crash test dummy.