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Railways Shock Absorber Test System
The Railways Shock Absorber Test System is a servo-hydraulic testing platform designed to evaluate the performance of rail vehicle suspension dampers, including both primary and secondary shock absorbers used in locomotives, metro cars, and passenger coaches. The system applies controlled axial loads under real-world simulation to assess damper behavior across multiple load, displacement, and velocity conditions.
It supports dynamic testing in both vertical and lateral directions with configurable force and stroke capacities based on damper type. Core parameters such as damping force, displacement, velocity, hysteresis, and energy dissipation are measured with high precision. The system integrates high-speed data acquisition, customizable test control software, and compatibility with environmental chambers for temperature-dependent evaluations. It’s suitable for use in railway R&D labs, quality assurance departments, certification agencies, and OEM production facilities.
Specifications of Railways Shock Absorber Test System
| Feature | Details |
|---|---|
| System Model | BI-7080R |
| Actuation Type | Servo-hydraulic with vertical and lateral actuators |
| Max Force Capacity | ±80 kN (vertical), ±40 kN (lateral) |
| Max Stroke | ±125 mm (vertical), ±25 mm (lateral) |
| Max Frequency | Up to 10 Hz |
| Test Modes | Sinusoidal, sweep, random, transient, custom waveform |
| Supported Dampers | Primary and secondary dampers for bogie testing |
| Data Acquisition | High-speed, real-time display with integrated control |
| Sensor Integration | Force transducers, LVDTs, velocity transducers |
| Software Platform | BISS-developed GUI with waveform editor, data logging, and auto-reporting |
| Safety Features | Emergency stop, overload protection, system diagnostics |
| Optional Add-ons | Environmental chamber, camera-based damper motion capture |
| Compliance | UIC, RDSO, EN, ISO standards |
| Applications | Performance and endurance testing for railway shock absorbers |
| Power Requirements | Standard 3-phase industrial supply |
Key Features of the Railways Shock Absorber Test System
1. Dual-Column Load Frame with Tiltable Actuator Mount
- Rigid two-column structure ensures stable loading and test repeatability
- Equipped with a bottom-mounted actuator for efficient force transmission
- Hydraulic or manual tilting of the load frame allows testing at user-defined angles from 0° to 90°, enabling simulation of both vertical and inclined damper orientations
2. Advanced Servo-Hydraulic Actuation System
- Delivers smooth, programmable dynamic motion with servo valve control
- Engineered to simulate both static and high-speed dynamic damper responses
- Capable of operating across a wide frequency range of 0.001 to 200 Hz
3. Comprehensive Damper Evaluation Capabilities
- Supports testing for seal friction, gas charge pressure, static force, and dynamic response under real-world simulation
- Allows full-cycle performance mapping across various speeds, displacements, and temperatures
4. High-Precision Sensors and Control
- Features 24-bit analog data acquisition and 32-bit digital encoder inputs, ensuring high-resolution feedback
- Achieves ±0.5% readout accuracy across stroke, load, and strain channels (±0.25% optional)
- Displacement resolution of 0.5 µm standard, with an option for ultra-fine 0.1 µm resolution
5. Modular Fixture System with Quick-Change Tooling
- Jaw faces and spacers are easily replaceable, reducing test setup time between different damper types
- Compatible with a wide range of shock absorber sizes and mounting styles (primary and secondary suspension)
6. Energy-Efficient Hydraulic System
- Includes a low-noise, servo-controlled hydraulic pump
- Reduces energy consumption by up to 60% compared to conventional systems
- Maintains consistent performance with operating pressure up to 210 bar
7. Robust and Reliable System Architecture
- Built with contamination-insensitive servo-hydraulics, ensuring minimal performance degradation over time
- Uses readily available commercial off-the-shelf (COTS) spares, simplifying maintenance and support
8. Environmental and Electronics Protection
- All electronic and electrical components are housed in dustproof, air-conditioned enclosures for long-term reliability
- Designed to operate in harsh testing environments with temperature and humidity variation
9. High Column Clearance and Expandability
- Offers 600 mm vertical column clearance as standard, with extra vertical daylight options available
- Accommodates longer dampers used in heavy-duty railway and metro suspension systems
10. Multi-Voltage Hydraulic Power Options
- Supports 380/400/415 VAC, 3 Phase, 50/60 Hz electrical input
- Suitable for global railway labs and manufacturing environments with varied power standards
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Applications of the Railways Shock Absorber Test System
1. Railway OEMs and Bogie Manufacturers
- Used to test and validate shock absorbers for primary and secondary suspension systems in locomotives, coaches, metro cars, and high-speed trains
- Supports design verification and product qualification for new damper models
2. Rolling Stock Maintenance Depots and Refurbishment Units
- Enables periodic performance evaluation and revalidation of in-service dampers during scheduled overhauls
- Helps identify performance degradation and assists in predictive maintenance programs
3. Railway Component Manufacturers and Tier-1 Suppliers
- Essential for end-of-line quality checks on dampers before dispatch
- Ensures product compliance with customer specifications and international standards (UIC, EN, RDSO)
4. Railway Research and Development Laboratories
- Supports functional testing, force-displacement analysis, and hysteresis characterization for damping components under simulated operating conditions
- Useful for studies involving passenger comfort, ride quality, and vibration control
5. Certification and Test Facilities
- Applied in regulatory testing to certify shock absorber designs as per railway compliance protocols
- Ideal for third-party validation, safety approvals, and contract-based conformance checks
6. High-Speed Rail Engineering Programs
- Assesses damper behavior under high dynamic loads typical of fast rail transit systems
- Useful in development of NVH-optimized suspension systems for noise and vibration reduction
7. Urban Transit and Metro Rail Projects
- Used to validate dampers for short-radius curves, frequent braking, and start-stop cycles in metro and LRT systems
- Helps ensure passenger comfort and vehicle stability in dense urban environments
8. Academic and Research Institutions
- Supports laboratory research and educational training on railway suspension technologies
- Used for experimental validation, design prototyping, and system-level integration studies