Johnson Controls develops new hip-point mannequin that complies with 3 different international standards

February 20, 2013: Hip-point mannequins are an indispensible element in the engineering and production of automotive seating. They are used to measure whether a vehicle can safely and comfortably accommodate the driver and passengers. Since there are three different international standards that define the characteristics and dimensions of these mannequins, automakers and suppliers use various models.

Automotive seating manufacturer Johnson Controls has now developed a hip-point mannequin that complies with all three standards.

"As a technology leader in automotive seating, we measure and test our products every day in order to ensure the greatest possible safety and optimal comfort," said Wilfried Beneker, vice-president engineering, product business unit metals and mechanisms at Johnson Controls Automotive Seating. "Until now, however, there was no single hip-point mannequin on the market that satisfied all three standards and our high requirements. Therefore, it made sense for our engineers to design their own mannequin."

The new hip-point mannequin meets standards set by the Society of Automotive Engineers (standard SAE J 826), the central specification for hip-point mannequins worldwide, and the GLORIA standard for EuroNCAP tests. In addition, it also satisfies recommendations of the German Association of the Automotive Industry VDA (recommendation VDA 304).

The hip point plays a key role in the development of automotive seating. It is the seating reference point (SgRP) in digital design plans. Measurements are defined from this point in the vehicle, including the distance to the steering wheel and gas pedal and the driver's field of vision. Using a hip-point mannequin, the position of the driver and passengers can be measured in prototypes and as well as in the actual vehicle and then compared with the design plans.The measuring mannequin from Johnson Controls, with its carbon torso, can also be fitted with a head restraint measurement device (HRMD). This determines the position of the head in relation to the head restraints.

The engineers at Johnson Controls have also developed a procedure for calibrating the hip-point mannequin and head restraint measurement device. The mannequin is clamped into a calibration device and measured with a 3D coordinate measuring machine. An optical 3D scanning system is used to test that the carbon torso shell fully meets all standards after production as well. This method ensures an especially high degree of measurement accuracy and precise reproducibility of the process. In addition, the engineers have also defined a detailed but user-friendly calibration log. This allows users of the mannequin and head restraint measurement device to easily check adherence to the detailed specifications contained in the three standards.

Johnson Controls has been using the hip-point mannequin since June 2011. Following in-house practical testing for a year and a half, the company is now offering the mannequin to automakers, other manufacturers of automotive seating and external testing organisations.

"The response to our mannequin has been extremely positive. Several automakers have already shown interest in it," said Beneker.