As technology advances, pressure to reduce energy use intensifies, consumer expectations for comfort rise, and demands for clothing and indoor climate control become increasingly stringent. These goals, in turn, require advanced and reliable analytical methods that can faithfully correlate with human thermal behavior and sensory perception. Over the past two decades, the parallel development of simulation tools for human temperature regulation and thermal manikins has been rapidly and continuously evolving. Recent advances in computing technology have facilitated computer simulations of the complex human thermophysiological regulation mechanisms with high spatial and temporal resolution. Improvements in manufacturing techniques and control strategies have led to the development of highly sophisticated thermal manikins. These versatile evaluation instruments combine fine spatial resolution with high measurement reliability and system responsiveness. When combined with thermophysiological models, thermal manikins become adaptive manikins capable of mimicking realistic, dynamic human thermophysiological responses to a given environment. Several such manikins are already in use, primarily in clothing research but also in built environment research.
Thermal manikins are instruments that simulate heat and moisture exchange between the human body and the environment and are widely used in clothing, construction, environmental research, aerospace, fire protection, and traffic safety. Especially in the evaluation of thermal and moisture comfort of clothing and the development of occupational protective clothing, the thermal manikin can simulate the heat exchange process between the human body, clothing and the environment in a set environment, and scientifically evaluate the overall thermal performance of the clothing, thereby avoiding the influence of individual differences in human experiments. The experiment has high accuracy and good repeatability, and is recognized as an indispensable means for clothing ergonomics research.
Professor P. Ole Fanger of the Technical University of Denmark (DTU) pioneered the use of a thermal manikin in indoor environment and human thermal comfort assessment. In 1979. team member Peter Trans successfully installed a new generation of control systems on the manikin at DTU. This new thermal manikin was used in numerous research projects in the following years.
Over the following decades, the thermal manikin was continuously improved and updated to meet the research needs of DTU, and gradually became involved in research and testing projects by many renowned international researchers.
In 1988. Peter Trans founded a technology company dedicated to the development of thermal manikins, and the new generation of thermal manikin has been sold worldwide.
The upper and lower body are modular and can be freely attached and detached.
This design facilitates the use of various garments on the manikin, making it particularly suitable for use in the textile and apparel industry, where it is used to test the thermal resistance (CLO) value of clothing.
Independent Zone Control
The dummy is divided into 22 standard zones. The temperature and heat index of each zone can be independently controlled and measured. Experimental values can be obtained for each zone individually, or grouped numerical calculations can be performed using a weighted average.
This design is also particularly suitable for testing the thermal resistance of clothing, footwear, and headgear. It can test the thermal insulation performance of full-body clothing, as well as average the CLO values of individual items such as tops, pants, gloves, and hats. It can even analyze and compare thermal performance differences between different parts of the same thermal garment, such as the front, back, sleeves, and collar, due to different materials or craftsmanship.
Thermal manikins have a wide range of applications. Like versatile "testers," they play an irreplaceable role in numerous industries. Let's take a closer look at the impressive performance of thermal manikins in various fields.
In the fashion world, thermal manikins are considered the unsung heroes behind the scenes. When designers conceive a new garment, thermal manikins serve as the first "fitting models." By simulating human sweating under various motions and environmental conditions, they provide designers with precise data on the garment's breathability and perspiration management.
For example, a well-known sports brand used thermal manikins to conduct a series of rigorous tests while developing new running gear. In a simulated high-temperature and high-humidity environment, the thermal manikins followed the motion patterns of running, and the new running gear they wore withstood the test. Data collected by sensors showed that the running gear quickly evaporated sweat, keeping the body dry, while also being extremely breathable and preventing athletes from feeling stuffy. This result gave designers confidence in the product, and the running suit ultimately became a huge success in the market, beloved by runners. For example, some high-end outdoor brands use thermal manikins to simulate the human body in extreme cold before launching new cold-weather clothing. After the manikins are fitted with cold-weather clothing and continuously work in low-temperature environments, monitoring their surface temperature and heat loss allows designers to accurately determine whether the clothing's thermal insulation performance meets standards and which areas require further optimization.
In the challenging field of aerospace, thermal manikins also shoulder a vital role. They are used to simulate astronauts' physiological responses in space, providing critical data for the design and improvement of spacesuits. The space environment is extremely harsh, with vast temperature variations, from extremely cold to scorching, coupled with strong radiation and microgravity. Spacesuits must not only provide excellent thermal insulation but also effectively block radiation to maintain the astronaut's vital signs.
During the development of the Shenzhou series of spacecraft, researchers conducted extensive experiments using thermal manikins. In a simulated space environment of alternating high and low temperatures, thermal manikins, wearing different versions of spacesuits, withstood various extreme conditions. By analyzing various data from the thermal manikins, researchers continuously optimized the materials and structural design of the spacesuits. For example, during one experiment, researchers discovered that the thermal manikin's hands cooled rapidly in low temperatures. Consequently, they improved the spacesuit's hand insulation, adding a special insulation layer and heating elements to ensure that astronauts' hands remained flexible and warm during extravehicular missions. These improvements, based on the thermal manikin experiments, have significantly improved the performance and safety of spacesuits, safeguarding my country's space program.
Firefighters are heroes of peacetime, bravely blazing flames to protect lives and property. Thermal manikins are their trusted assistants. In the field of fire protection, thermal manikins are used to test the performance of protective clothing to ensure that firefighters are adequately protected during their missions. Fire scenes are extremely hot, accompanied by smoke and toxic gases. Firefighting protective clothing must possess excellent thermal insulation, fire resistance, and breathability.
Before purchasing new firefighting protective clothing, the fire department conducts rigorous testing using thermal manikins. The manikins are placed in a simulated fire scene's high-temperature environment and fitted with the protective clothing to be tested. The thermal manikins' surface temperature and heat flux are monitored to evaluate the thermal insulation performance of the protective clothing. For example, in one test, a manikin wearing a new firefighting protective clothing was exposed to temperatures of 1000°C for 30 minutes. After the test, data analysis confirmed that the protective clothing effectively blocked heat transfer, keeping the manikin's surface temperature within a safe range, thus buying firefighters more time at the fire scene. Furthermore, the thermal manikin simulates the sweating of firefighters during various physical activities, allowing for testing of the protective clothing's breathability and ensuring that overheating does not impair the firefighters' mobility.
As people's demand for automotive comfort continues to grow, automakers are continuously striving to improve the comfort of their in-car environments. Thermal manikins play a crucial role in this process, being used to test the thermal comfort of components such as car seats and air conditioning systems, providing consumers with a better driving experience.
The comfort of car seats directly impacts the experience of drivers and passengers. To design more comfortable seats, automakers use thermal manikins for seat thermal comfort testing. The manikins are placed on car seats to simulate passengers of varying body shapes and sitting postures. Sensors measure the temperature and pressure distribution at the points of contact between the manikins' bodies and the seat. For example, an auto company conducted multiple tests using thermal manikins while developing seats for a new model. Analysis of the test data revealed that the lumbar support area of the seat was overheating, causing discomfort to passengers after prolonged riding. Designers then improved the seat's lumbar support structure by adding ventilation holes and heat-dissipating materials, effectively reducing lumbar temperature and improving seat comfort.
The performance of the car's air conditioning system is also a significant factor influencing driving comfort. Thermal manikins simulate the human body's thermal sensation under varying ambient temperature and humidity conditions, enabling testing of the cooling, heating, and ventilation effectiveness of automotive air conditioning systems. In the automotive environmental laboratory, these manikins are placed inside vehicles and set to various air conditioning operating conditions. By monitoring the manikins' surface temperature, skin humidity, and other data, the performance of the air conditioning system is evaluated. For example, in high summer temperatures, the cooling speed and uniformity of the vehicle's air conditioning are tested; in cold winter conditions, the heating effectiveness and in-vehicle temperature distribution are tested. These tests enable automakers to optimize air conditioning system designs and enhance in-vehicle comfort.
