Servo-Hydraulic Dual Station Shock Absorber Test System

Servo Hydraulic Dual Station Shock Absorber Test System

High Precision Electromechanical Testing Machines for Advanced Industrial Applications

Servo Hydraulic Dual Station Shock Absorber Test System

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.

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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