Develops and manufactures hydrostatic shock absorbers, spring elements and test rig systems for rail technology, heavy industry and hydraulic engineering.
Hydrostat International GmbH
HertenNew on Amplifa
About HYDROSTAT
Hydrostat International GmbH, based in Herten, develops and manufactures hydrostatic shock absorbers, buffers, spring elements and viscoelastic chain tensioners as well as customised test rig solutions. On the market since 1995, the company is one of the first providers of hydrostatic shock absorbers in Germany and has sold more than 50,000 shock absorbers to date. Its range of services extends from consulting through design and calculation with Autodesk INVENTOR 3D, Ansys, CFD and SimulationX to the manufacture of prototypes and series products, assembly, commissioning as well as service and repair. Products are made, among other things, from stainless steel and carbon and are filled with non-toxic viscous or viscoelastic fluid. Fields of application include rail technology (coupling buffers, front-end equipment of metros and trams), heavy industry (springs for rolling mills, chain tensioning systems), hydraulic engineering (lock buffers, damped guide rollers for lift gates) as well as industrial applications and special designs. Quality assurance is carried out on in-house dynamic, static and endurance test rigs at the Herten site.
- Site
- Herten
- Processes
- Dynamic impact tests (test rig), Static load tests (test rig), Computer-controlled endurance tests (test rig), Magnetic particle surface crack testing, Ultrasonic testing, Manufacture of hydrostatic shock absorbers, Coupling shock absorbers / coupling buffers, Lock shock absorbers / lock buffers
- Materials
- Stainless steel, Carbon, non-toxic filling (viscous fluid / viscoelastic fluid), Viscous/viscoelastic fluid
- Certificates
- 100% testing before delivery, Dynamic test rig (80 t, 44 m), Static test rig, Endurance test rig, Magnetic particle crack testing, Ultrasonic testing, 3-D coordinate measurement, ISO 9001
- Founded
- 1995
- Industries
- Rail technology, Heavy industry (rolling mills, chain tensioning systems), Hydraulic engineering (locks, dams, bridges, coastal protection), Industrial applications, Special designs
- 01
Consulting
- 02
Development & Engineering (design, calculation, simulation)
- 03
Manufacturing (prototypes to series production)
- 04
Non-destructive material testing
- 05
Testing on in-house test rigs
- 06
Assembly & commissioning
- 07
Logistics
- 08
Service, repair & maintenance
Materials & Processes
Stainless steel
Used in pistons and bearings of lock buffers as well as in damped springs for guide rollers on lift gates in hydraulic engineering.
Carbon
Carbon-reinforced cylinder bodies reduce the weight of shock absorbers by 30 percent or more depending on the design.
Viscous/viscoelastic fluid
Non-toxic filling of the shock absorbers for static and dynamic damping of the applied forces.
Sites
Herten
DEHeadquarters, manufacturing, development and testing
- Lot size
- Prototypes to series production
- Materials
- Stainless steel, carbon, viscous/viscoelastic fluids
- Dynamic test rig (80 t maximum load, 44 m track length, approx. 6 m/s impact speed)
- Static test rig
- Endurance test rig
- 3-D coordinate measuring machine
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Dynamic impact tests (test rig)Testing | – | 44 m (track length) | Maximum load 80 tonnes | – | – |
| Static load tests (test rig)Testing | – | – | – | – | – |
| Computer-controlled endurance tests (test rig)Testing | – | – | – | – | – |
| Magnetic particle surface crack testingTesting | – | – | – | – | – |
| Ultrasonic testingTesting | – | – | – | – | – |
| Manufacture of hydrostatic shock absorbersAssembly | – | – | – | Prototypes to series production | Stainless steel, Carbon |
| Coupling shock absorbers / coupling buffersAssembly | – | – | – | – | – |
| Lock shock absorbers / lock buffersAssembly | – | Lift ≥ 1,000 mm | – | – | Stainless steel |
| Tension-compression shock absorbersAssembly | – | – | – | – | – |
| Buffers with deformation tubeAssembly | – | – | – | – | – |
| Destructive rolling bellows shock absorbersAssembly | – | – | – | – | – |
| Adjustable shock absorbersAssembly | – | – | – | – | – |
| Shock absorbers with RFID chipAssembly | – | – | – | – | – |
| Non-rebound shock absorbersAssembly | – | – | – | – | – |
| Springs for rolling millsAssembly | – | – | – | – | – |
| Damped springs for guide rollers on lift gatesAssembly | – | – | – | – | Stainless steel |
| Viscoelastic chain tensionersAssembly | – | – | – | – | – |
| Disc shock absorbersAssembly | – | – | – | – | – |
| Rotary shock absorbersAssembly | – | – | – | – | – |
| Hose shock absorbers (C-shape, S-shape)Assembly | – | – | – | – | – |
| Design and calculation (Autodesk INVENTOR 3D, Excel, Mathematica, Ansys, CFD, SimulationX)Engineering | – | – | – | – | – |
| Prototype construction & test proceduresEngineering | – | – | – | – | – |
| Assembly and commissioning of test rig systemsAssembly | – | – | – | – | – |
| 3-D coordinate measurementTesting | – | – | – | – | – |
| Service, repair, maintenance, retrofit of test rig systemsAssembly | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Dynamic test rig | HYDROSTAT | – | Track length 44 m, maximum load 80 t, max. impact speed approx. 6 m/s, covered measuring technology | – | Herten |
| Static test rig | HYDROSTAT | – | static load tests, high-precision sensor technology | – | Herten |
| Endurance test rig | HYDROSTAT | – | computer-controlled simulation of long-term loads | – | Herten |
| 3-D coordinate measuring machine | – | – | – | – | Herten |
Additional services
Reference customers
Quality & Testing
Every buffer and every spring is 100 percent tested before delivery; testing includes static tests, dynamic impact tests, computer-controlled endurance tests and non-destructive material tests (magnetic particle crack testing, ultrasonic testing). A data chip (RFID) is integrated into every product and a quasi-static force-displacement diagram is documented.
| Evidence | Herten |
|---|---|
| 100% testing before delivery | |
| Dynamic test rig (80 t, 44 m) | |
| Static test rig | |
| Endurance test rig | |
| Magnetic particle crack testing | |
| Ultrasonic testing | |
| 3-D coordinate measurement | |
| ISO 9001 |
History
- 1995
Foundation of the business with hydrostatic shock absorbers; start of implementing innovative test rig solutions and damping technologies; among the first providers of hydrostatic shock absorbers in Germany and European market pioneers
- bis heute
More than 50,000 shock absorbers sold