True Body Weight Ingress Egress Tester
The True Body Weight Ingress/Egress Tester is a specialized machine designed to evaluate either a complete automotive seating system or individual seat components. It provides realistic simulation of human ingress and egress movements, including dynamic interaction with seat cushions, upholstery, and the underlying mechanical structure. The tester can even assess the wear and durability of the occupant’s clothing during repeated use.
Application
The simulated human entry/exit seat test bench employs pneumatic servo control to simulate human entry and exit tests for automotive seats, measuring load, displacement, angle, and other parameters.
Standards
SAE J826-2002 – Anthropomorphic Test Devices for Vehicle Seating Systems
QC/T 740-2017 – Automotive Seat Fatigue Test Standard
Industry standards for automotive seat ingress and egress durability
Features
Four servo-electric motor-driven axes and three pneumatic functions for realistic movement.
Simulates in & out, right & left, up & down, rotation, free weight drop & recapture, and independent leg motion.
True body weight simulation (35–100kg) for realistic dynamic loading, including inertia effects.
Concurrent and programmable motion sequences for highly life-like testing.
Evaluates seat cushion, backrest, frame, foam, and fabric durability under repeated entry and exit cycles.
Adjustable test frequency, amplitude, and cycle count with automatic stop at the end of the test.
Parameters
| Parameter | Specification | Notes |
|---|---|---|
| Dummy Model | 3D indenter, 50% SAE J826-2002 | Wrapped with 12mm foam and denim |
| Pressure Head Weight | 44.5 kg | Adjustable for different test scenarios |
| Horizontal Slide | ~25 mm into cushion | Inner rear first with 30° rotation |
| Load on Pressure Head | 445 N | Maintained during creep and exit cycles |
| Rotation Angle | 30° | Simulates realistic entry angle |
| Experimental Frequency | 4.5 cycles/min | Adjustable |
| Number of Experiments | 15.000 simulated ingress/egress cycles | — |
Accessoriess
Pointer glass cover: Typically made of thickened tempered glass or acrylic, providing explosion-proof, scratch-resistant, and impact-resistant properties.
Washer: Located between the bottom of the scale and the platform, serving to absorb shock and stabilize the scale.
Zero-adjustment screw: Allows the pointer to accurately return to zero when unloaded by fine-tuning the balance system.
Weight weight: Used to measure weight.
Hook: Used to secure the weight.
Height ruler: Used to measure height.
Electronic height meter: Used to measure both height and weight.
Test Procedures
Prepare the 3D dummy indenter according to SAE J826-2002 standards. Wrap with foam and denim, and add weight to simulate realistic human mass.
Secure the seat assembly on the test bench and adjust to design position.
Program the robot motion for simulated human entry/exit:
Horizontal slide of pressure head into seat, rotating 30°
Align center line of pressure head with seat center
Creep and stabilize pressure head within the seat
Maintain 445 N load while sinking into seat
Continue creep against backrest at 30°
Maintain 445 N load as pressure head is halfway out
Slide along seat cushion edges during exit, simulating edge indentation
Start the test cycle; machine automatically repeats motions at set frequency.
Stop automatically after 15.000 simulated cycles and inspect seat for damage.
Safety and Maintenance
Ensure proper calibration of servo-electric axes and pneumatic actuators.
Check dummy and pressure head integrity before testing.
Maintain and inspect all mechanical and pneumatic components regularly.
Emergency stop and overload protection are built-in for operator safety.
Clean and lubricate moving parts as per manufacturer instructions.
FAQ
1. Why is the tester set to 4.5 cycles per minute for ingress/egress tests?
This slower speed (compared to vibration tests) allows the foam and upholstery to "react" and recover between movements, more accurately reflecting how a human slowly sits and pivots. It also prevents unnatural heat buildup in the seat materials.
2. Can this system simulate different occupant sizes?
Yes. By adjusting the weight plates on the pressure head and reprogramming the servo axes, you can simulate a wide range of occupants, from a 5th percentile female to a 95th percentile male.
3. What is the significance of the 12mm foam wrap on the dummy?
The foam wrap simulates the soft tissue of the human body. Without it, the hard plastic indenter would create unrealistic "pressure spikes" that could damage the seat fabric prematurely, leading to inaccurate durability data.
4. How does the system detect a seat frame failure?
The software monitors the displacement and load relationship. If a frame crack occurs, the indenter will likely "sink" further than programmed or the resistance force will drop, triggering an automatic safety stop and alert.
5. Is it possible to test the durability of seat bolsters specifically?
Absolutely. By programming a heavier rotation and "slide-in" motion, you can focus the impact and friction on the side bolsters, which are typically the highest-wear areas during vehicle entry and exit.
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