Servo Hydraulic Dual Station Shock Absorber Test System
High Precision Electromechanical Testing Machines for Advanced Industrial Applications

The Servo-Hydraulic Dual Station Shock Absorber Test System is a compact, high-precision solution designed for advanced damper testing in automotive suspension systems. Built for dual-station operation, it enables independent or simultaneous testing of two shock absorbers, increasing productivity and reducing test time in both development and production lines. With a crank-operated servo-hydraulic mechanism, the system delivers accurate sinusoidal displacement up to ±75 mm and frequencies reaching 6 Hz, closely replicating real-world driving loads.
Optimized for passenger cars, commercial vehicles, and two-wheelers, this test system integrates closed-loop servo control, high-speed data acquisition, and BISS software for waveform generation, live monitoring, and automatic report creation. Its robust, space-saving frame supports a variety of damper types — including mono-tube, twin-tube, hydraulic, and oil-gas shock absorbers — making it ideal for automotive labs, OEMs, and suspension component manufacturers seeking durability, reliability, and efficiency in damper testing.
Specifications of Servo Hydraulic Dual Station Shock Absorber Test System
Feature | Details |
---|---|
Test Stations | Dual (Independent or Simultaneous Operation) |
Force Capacity | 8 – 25 kN Dynamic Load Rating |
Velocity Range | 0.005 – 3.5 m/s |
Displacement | ±75 mm |
Frequency Range | Up to 6 Hz |
Actuation | Servo-Hydraulic with Crank Mechanism |
Tooling Compatibility | 2, 3, 4-Wheeler Shock Absorbers, Eye/Thread Mounts |
Grip System | Low-force Bulldog Top Grip with Hold-Down Press |
Hydraulic System | Hard-Piped, Air-Cooled, No Water Needed |
Pump Efficiency | Low Noise, 60% Lower Power Consumption |
Enclosure | Dust-Proof, Air-Conditioned Electronics Cabinet |
Control Software | BISS Test Interface with Custom Profiles & Reports |
Optional Sensors | Seal Verification, Part Detection, Removal Sensors |
Power Requirements | 3-Phase AC, Standard Mains + Compressed Air |
Certifications | CE Compliant, Industrial Safety Standards |
Key Features of Servo-Hydraulic Dual Station Shock Absorber Test System
1. Asynchronous Dual-Station Operation
- Test two dampers independently or simultaneously with full control over each station.
- Doubles productivity while offering immediate cross-reference of test results between specimens — ideal for comparative and batch testing.
2. Compact, Fully Integrated Design
- All system components — including hydraulics, electronics, and actuation — are packed into a single footprint for space efficiency.
- Requires only a standard mains and compressed air connection to operate, making it highly portable and easy to relocate within the shop floor.
3. Proprietary Energy-Efficient Hydraulic System
- Features a low-noise, servo-controlled pump that consumes up to 60% less energy than conventional hydraulic systems.
- Fully hard-piped hydraulics eliminate the use of flexible hoses, ensuring long service life and leak-free operation.
- Built-in air-cooled system eliminates the need for external water connections.
4. Dust-Proof and Temperature-Controlled Electronics Enclosure
- All electronics and electrical components are housed in a sealed, air-conditioned cabinet, protecting sensitive systems from dust, humidity, and temperature variations — ideal for rough production environments.
5. Wide Force and Velocity Range
- System configurations available with dynamic force ratings from 8 to 25 kN, and velocity capabilities ranging from 0.005 to 3.5 m/s, supporting various automotive damper types and test profiles.
6. Pneumatic Tooling with Self-Alignment
- Equipped with pneumatic jaw tooling offering full 3-degree freedom of rotation at both ends, ensuring self-alignment and accurate axial force application during tests.
7. Modular Tooling for Multi-Vehicle Compatibility
- Custom-designed tooling interfaces support shock absorbers and suspension components for 2-wheeler, 3-wheeler, and 4-wheeler platforms.
- Supports threaded, eye-type mounts, front forks, and a variety of strut types using interchangeable fixtures.
8. Rapid Part Setup and Changeovers
- Quick-change jaw faces and spacers simplify the transition between different part sizes and geometries, minimizing downtime and boosting testing throughput.
9. Built-in Hydraulic Press & Hold-Down Assembly
- Integrated press unit supports rod-assembly insertion and allows testing of unsealed parts. This enables both pre-assembly validation and functional testing in a single station.
10. Specialized Low-Force Gripping System
- “Bull-dog” style low-force top grip securely holds the damper without damage while still resisting applied tensile and compressive forces during damping evaluations.
11. Contamination-Resistant Design with COTS Components
- Features contamination-insensitive servo-hydraulics, increasing reliability in industrial conditions.
- Uses commercial off-the-shelf (COTS) spares for easy maintenance and minimal downtime.
12. Optional Part Detection Sensors
- Integrated part presence sensors ensure a part is loaded before testing begins, avoiding duplicate tests or false data.
- Additional sensors verify complete seal insertion and flag unsealed parts, enhancing quality control during R&D and production cycles.
Applications of the Servo-Hydraulic Dual Station Shock Absorber Test System
1. Automotive OEMs and Tier-1 Suppliers
Used for development, validation, and production testing of suspension systems. Essential in:
- Passenger car, SUV, and two-wheeler damper testing
- Ensuring component durability, performance, and compliance with global standards
- Integrating with end-of-line testing in mass production
2. Commercial Vehicle and Off-Road Equipment Manufacturers
Applied in testing large and heavy-duty dampers for:
- Buses, trucks, construction machinery, and agricultural vehicles
- Verifying damping force under extreme loads and harsh environments
- Fatigue testing for extended life cycles and heavy-duty usage
3. Suspension System R&D Laboratories
Ideal for vehicle dynamics and suspension researchers in:
- Developing new damper technologies, including oil-gas hybrid and adjustable dampers
- Studying rebound, compression, hysteresis, and thermal behavior
- Benchmarking dampers from various suppliers or design iterations
4. Component and Subsystem Validation Centers
Deployed in centralized validation departments that handle:
- Qualification of suppliers’ shock absorber parts
- Regulatory compliance checks (ISO, ASTM, SAE standards)
- Cross-platform performance benchmarking (2W, 3W, 4W)
5. Electric Vehicle (EV) and New Mobility Manufacturer
Used to test new-generation dampers for:
- Lightweight suspension systems in electric scooters, bikes, and compact EVs
- Smart, adaptive, and electronically controlled suspension technologies
- Integration into lightweight chassis and modular vehicle designs
6. Defense and Military Vehicle Applications
Supports robust validation of heavy-duty dampers for:
- Armored vehicles, tactical off-road transports, and military trucks
- High-reliability damping under blast shock and rugged terrain conditions
- Long-life and high-cycle validation for mission-critical applications
7. Academic Institutions and Automotive Research Organizations
Implemented in universities and R&D centers for:
- Suspension system simulation, validation, and experimental setups
- Comparative studies between conventional and intelligent damper systems
- Supporting capstone projects, design testing, and Ph.D. research
8. Quality Assurance and End-of-Line Test Facilities
Perfect for manufacturing plants where:
- Each damper must be tested before dispatch
- Sensors detect unsealed or misassembled parts
- Cycle-time optimization and automatic report generation are required