Custom Thermal Manikin Testing System

In order to ensure that the power consumption of the standard panels did not exceed 180 kW, we conducted additional computer simulations. The calculations indicated that by modifying the structural design, it was possible to increase the efficiency of each panel.

By integrating reflectors into the thermal panel design, we increased efficiency by 30% and improved energy distribution. This allowed us to meet the required heat flux using only two panels instead of three, keeping the system within the 180 kW power limit.

After incorporating reflectors, the thermal panel exhibited the following characteristics: Efficiency (Coefficient of Performance) – 80% (a 30% increase); the distance from the panel at which a value of 40 kW/m2 was achieved – 15 cm. This solution resolved the energy consumption issue, as only 2 panels were now sufficient for testing the mannequin, instead of the initially required 3. Beyond the technical gain, this reduced the system’s energy demands, simplified installation, and lowered long-term operating costs.

Implementing reflectors around the lamps of the thermal panels increased efficiency by 30%. Energy consumption was reduced by 1.5 times, as the enhanced efficiency of individual panels meant that only two units were required to achieve the necessary temperature for heating the space and manikin.

To implement the manikin’s movement mechanism, we needed to consider the room dimensions, the influence of high-temperature open flame, and ventilation ducts placement. We opted to develop a crane-beam system, as floor-mounted solutions occupied too much space and interfered with ventilation.

With a room height of 3 meters, the crane-beam was designed to allow unrestricted movement for an adult at full height.

However, the ventilation issue persisted, as our crane-beam design still couldn't accommodate the ventilation structure. Subsequently, we relocated the air ducts outside, while air intake was maintained inside the facility.

Our initial goal was to fully adapt the system to the facility’s existing conditions — spatial limitations, safety standards, and ventilation layout. When that wasn’t enough, we proposed a minimal layout change to ensure proper ventilation without compromising usability.

This reflects our flexible approach: we aim to fit the system to the environment wherever possible, but we’re also ready to lead facility-level decisions when they serve performance, safety, and cost-efficiency.

In addition to longitudinal movement, the manikin was to descend, ascend, and rotate 180° around its axis.

To achieve the required kinematics for the thermal manikin, we conducted calculations for moment of inertia and moment of friction. For rotation around its own axis, we employed a single-stage worm gear motor-reducer, chosen for its minimal inertial moment to avoid significant additional weight on the manikin. This approach was crucial to facilitate the selection of an actuator for vertical movement. The relatively low mass of the chosen rotation drive allowed us to use commercially available linear rod actuators with a piston speed of 10 mm per second.

With all key constraints resolved — including power limitations, spatial restrictions, and movement requirements — the system was delivered and successfully integrated into its operational environment. The project reached TRL 9, with the solution now functioning as a complete, real-world testing system.