Bomb Shell Hydraulic Pressure Testing Machine Upto 1200-1800-Bar

Bomb Shell
Hydraulic Pressure Testing Machine

Automated hydrostatic pressure testing for artillery shells, mortar rounds, and industrial pressure vessels. Select your ammunition, choose your capacity, and configure the machine to your exact production needs.

1800

Bar Structural Capacity

200+

Shells / Hour (Top Model)

1 µm

Deformation Resolution

Calibers Supported

ABB robot handling artillery shells on roller conveyor

Robotic Shell Handling

155mm shells on conveyor with hydraulic press and ABB robot

Automated Testing Cell

Production line conveyor system with safety fencing

Production Line Installation

Testing Process

How the Bomb Shell Works

Every model follows this proven 5-stage testing cycle. Higher models simply run multiple cycles in parallel.

Load & Position

Operator places shells horizontally on the infeed conveyor using the jib crane. The 6-axis robot (ABB/KUKA/FANUC, 150 kg payload) picks each shell and positions it vertically on the 4-station rotary index table.

VFD gear motor-driven roller conveyor
Robot with hydraulic gripper for secure handling
Automatic shell identification and recipe selection

Fill & Measure Cavity Volume

The shell cavity is automatically filled with filtered water mixed with a rust-inhibiting compound. A high flow rate fills the bulk volume, then switches to a precision low flow as the level approaches the eye face. The exact equivalent water capacity is measured and recorded.

Dual-rate filling: high-speed bulk + precision top-off
Volume accuracy: ±1% (≤9 mL total uncertainty)
Resolution: ≤1 mL via volumetric flow meter
Capacity compliance check (upper/lower thresholds)

Seal & Pressurize

The rotary table indexes 90° to the testing station. The 100-tonne hydraulic press pushes the shell against the sealing head. Air is purged, then dual hydraulic intensifiers ramp pressure up to the programmed setpoint (up to 1400 bar) with continuous monitoring throughout the dwell period.

Operating pressure: 250 – 1400 bar
Structural capacity: 1800 bar (1.5× safety factor)
Hold time: 5 – 60 seconds (programmable)
Pressure resolution: ≤1 bar, accuracy: ±2% / ±10 bar
Continuous pressure/time data acquisition at 250ms

Measure Deformation & Record

LVDT probes (Marposs/Renishaw) measure the shell's maximum expansion during pressurization and permanent deformation after depressurization. All data is automatically logged, and the shell is classified as pass or reject.

Resolution: 1 micron (LVDT / infrared non-contact)
Measures expansion during hold & deformation post-release
Automatic pass/fail classification with buzzer alert
Pressure vs. time curve recorded as CSV
Data acquisition frequency: 250 ms

Dewater, Stamp & Unload

The rotary table indexes to the dewatering station. A servo mechanism tilts the shell 45° to drain water into the collecting tray. Passed shells are stamped with an "H" mark, then the robot places them on the outfeed conveyor. Rejected shells are diverted to the rejection table automatically.

Servo motor tilt mechanism for complete drainage
Optional integrated drying (internal + external)
Micro-percussion / cold stamp marking ("H")
Automatic pass/reject sorting
Operator unloads from outfeed via jib crane

Ammunition Compatibility

Supported Shell Types

23 shell variants across 4 caliber families. All test parameters are PLC-stored per recipe — changeover takes under 3 minutes.

Shell Type	Designation / Models	OD (mm)	Length (mm)	Weight (kg)	Test Pressure	Compatible Machine
⬡ 105 mm Caliber 4 Types
Standard HE	OF-420, M1, DM111, M760	105	490–530	14–15	350–450 bar	BS-30
Training / TP	M60 TP, M67 TP-T, Practice LU	105	490	13–14	200–300 bar	BS-30
Smoke / WP	M60 WP, DM112 WP	105	490	14	300–400 bar	BS-30
Illumination	M314 Illum, Star Shell	105	540	13	250–350 bar	BS-30
⬡ 122 mm Caliber 4 Types
Standard HE	OF-462, OF-471, 3OF24	122	700–720	21–22	500–600 bar	BS-60
Rocket-Assisted (RAP)	9M521, OF-462 RAP	122	750–800	26–28	500–650 bar	BS-60
Cargo / Submunition	NORINCO Cargo, 9N210 Sub	122	800–830	25–27	400–500 bar	BS-60
Training / TP	TP-OF-462, Inert Practice	122	700	21	200–350 bar	BS-60
⬡ 127–130 mm Naval Caliber 3 Types
Naval HE — 130 mm	AK-130 HE, 3OF83	130	820–840	33–34	600–700 bar	BS-60
Naval HE — 127 mm	OTO Melara 127/54, Mk 64	127	800–820	31–33	600–700 bar	BS-60
Naval AA / GP	Bofors 120 mm, Mk 45 Mod 4	127	700–730	28–30	550–650 bar	BS-60
⬡ 155 mm Caliber 12 Types
Standard HE	M107, DM121, OF-540, L15	155	600–615	43–44	800–1000 bar	BS-120 BS-200
Long-Range HE (ERFB)	M795, LU211, BK-27, K307	155	600–625	43–45	900–1100 bar	BS-120 BS-200
Base Bleed (BB)	ERFB-BB, Assegai-BB, NORINCO BB, V-LAP BB	155	860–880	45–47	900–1100 bar	BS-200
Rocket-Assisted (RAP)	M549A1, ERFB-RAP, Chinese RAP	155	890–915	47–48	1000–1200 bar	BS-200
DPICM / Cluster	M864, K307 DPICM, DM642	155	780–800	46–48	900–1100 bar	BS-200
Smart / Sensor-Fused	BONUS, SMArt 155, M898 SADARM	155	890–910	48–50	1000–1200 bar	BS-200
Extended Range (ERCA / VLAP)	XM1113, VLAP, ERCA Projectile, BM-12	155	970–1005	47–50	1000–1400 bar	BS-200
Training / Practice	M795 TP, Inert M107, Practice LU211	155	600–620	43	400–600 bar	BS-120 BS-200
Smoke / WP	M110 WP, M825 WP, DM112 Smoke	155	695–720	42–44	600–800 bar	BS-120 BS-200
Illumination	M485 Illum, M118, IR Star Shell	155	755–780	43–45	600–800 bar	BS-120 BS-200
Thermobaric / FAE	Custom FAE Designs, OFB Thermobaric	155	Custom	~45	800–1000 bar	BS-200
Anti-Structure / Bunker Buster	DRDO Hardened, OEM Bunker Round	155	Custom	~50	1000–1400 bar	BS-200

≤ 600 bar Low Pressure 600–1000 bar Medium Pressure > 1000 bar High Pressure All parameters PLC-stored · Changeover < 3 min

Build Your Machine

Configure & Request a Quote

Select your ammunition types, choose capacity, pick optional features, and submit your configuration for a detailed quotation.

Ammunition

Capacity

Features

Review & Quote

Select the Ammunition Types You Need to Test

Click on each shell type you require. Expand for detailed specifications. You can select multiple types.

Choose Your Production Capacity

Based on your selections, we recommend the highlighted model. Each model shares the same 1800 bar structural capacity.

Add Optional Features

Toggle on any additional capabilities you need. Some features require Bomb Shell 60 or higher.

Review Your Configuration & Request a Quote

Specification	Bomb Shell 30	Bomb Shell 60	Bomb Shell 120	Bomb Shell 200
OUTPUT & PERFORMANCE
Testing Output	25–30/hr	50–60/hr	100–120/hr	180–200/hr
Cycle Time / Shell	~120s	~60s	~30s	~18s
Max Operating Pressure	1400 bar	1400 bar	1400 bar	1400 bar
Structural Capacity	1800 bar	1800 bar	1800 bar	1800 bar
MATERIAL HANDLING
Infeed Conveyors	1	1	2	3
Outfeed Conveyors	1	1	2	3
Rejection Conveyors	—	1	1	2
6-Axis Handling Robots	—	1 × 150kg	2 × 150kg	3 × 150kg
Loading Method	Jib Crane	Robotic	Robotic	Robotic
TESTING STATIONS
Sealing & Test Heads	1	1	2	4
Rotary Index Tables (4-station)	1	1	2	4
Hydraulic Intensifiers	1	2	3	5
AUTOMATION & CONTROL
PLC (Siemens S7-1200)	✓	✓	✓	✓
HMI Touchscreen	10"	10"	12"	15"
SCADA System	—	✓	✓	✓
MES Integration	—	—	Optional	✓
FOOTPRINT
Approx. Size (L × W)	6×4m	8×6m	14×7m	20×10m

Specification

Bomb Shell 30

Bomb Shell 60

Bomb Shell 120

Bomb Shell 200

OUTPUT & PERFORMANCE

Testing Output

25–30/hr

50–60/hr

100–120/hr

180–200/hr

Cycle Time / Shell

~120s

~60s

~30s

~18s

Max Operating Pressure

1400 bar

Structural Capacity

1800 bar

MATERIAL HANDLING

Infeed Conveyors

Outfeed Conveyors

Rejection Conveyors

—

6-Axis Handling Robots

—

1 × 150kg

2 × 150kg

3 × 150kg

Loading Method

Jib Crane

Robotic

TESTING STATIONS

Sealing & Test Heads

Rotary Index Tables (4-station)

Hydraulic Intensifiers

AUTOMATION & CONTROL

PLC (Siemens S7-1200)

✓

HMI Touchscreen

10"

12"

15"

SCADA System

—

✓

MES Integration

—

Optional

✓

FOOTPRINT

Approx. Size (L × W)

6×4m

8×6m

14×7m

20×10m

Standard Across All Models

Built for Defence-Grade Reliability

Every Bomb Shell machine shares these core capabilities.

⚖

1800 Bar Structural Capacity

100T hydraulic press with high-grade structural steel (IS:2062-2011). Chromium-plated sliding parts and precision-machined surfaces.

⚙

Siemens PLC + SCADA

Siemens S7-1200 PLC with ladder logic. HMI touchscreen with live process flow. SCADA kiosk for centralized monitoring and CSV data export.

📈

1 Micron Deformation Sensing

LVDT/infrared probes (Marposs/Renishaw) measure expansion during test and permanent deformation after. Automatic pass/fail classification.

🛡

Comprehensive Safety

E-stops, interlocks, safety fencing, closing guards, pressure alarms, leak detection. CE marked, globally compliant with defence safety standards.

🔃

Quick Changeover Tooling

Adjustable V-block fixtures, interchangeable sealing heads and location cups. Multiple test recipes stored in PLC for rapid shell-type changeover.

🌏

Global Defence Standards

AMS 2154 compliant. Supplied to Indian Ordnance Factories, Adani Defence, ST Engineering. NATO and non-NATO ammunition compatible.

FAQ

Common Questions

What is the maximum pressure rating of the Bomb Shell 1800-Bar testing machine?

The Bomb Shell hydraulic pressure testing machine is designed for a maximum continuous 1800 bar pressure rating (26,100 psi), ensuring reliable high-pressure validation for aerospace and defence-grade components. It is engineered with a safety margin and structural integrity suitable for MIL-STD-1522 compliance testing, proof pressure testing, and burst testing scenarios. This makes it ideal for qualification of critical pressure vessels, ammunition shells, and hydraulic actuator systems used in defence applications requiring stringent ADA approval and safety certification.

What types of hydraulic components can be tested on this equipment?

The system supports testing of a wide range of defence and aerospace components including bomb shells, pressure vessels, hydraulic actuators, manifolds, control valves, and tubing assemblies. It is particularly suited for high-pressure proof and leakage testing in accordance with MIL-STD-1522 and other defence testing protocols. Custom fixtures enable testing of different geometries and calibers, ensuring compatibility with artillery shells and aerospace-grade components requiring ADA approval and high-reliability validation.

What testing standards and compliance requirements does the system meet?

The Bomb Shell 1800-Bar system is designed to meet stringent defence and aerospace standards such as MIL-STD-1522 for pressure testing, along with customer-specific QA/QC protocols. It supports traceable test data logging for audit and ADA approval processes. The system can be configured to comply with ASME, ISO, and defence-specific acceptance criteria, ensuring suitability for high-pressure hydraulic actuator testing and safety-critical validation workflows.

Is the system suitable for production line integration?

Yes, the machine is designed for seamless integration into defence manufacturing lines. It supports SCADA-based control systems, microprocessor control, and optional MES connectivity for real-time data exchange. This enables synchronized testing workflows for hydraulic actuator testing, bomb shell validation, and aerospace component qualification. Integration ensures compliance with MIL-STD-1522 traceability requirements and supports centralized monitoring for ADA-approved production environments.

What safety features are included in the testing system?

The system incorporates multiple safety layers including pressure relief valves, burst containment shielding, interlocked enclosures, and emergency shutdown systems. These features are essential for high-pressure defence testing under MIL-STD-1522 guidelines. Operator safety is enhanced through automated test cycles, remote monitoring, and fail-safe controls. The design supports ADA approval requirements and ensures safe handling of explosive or high-risk components during hydraulic actuator testing.

Can the machine be customized for different shell sizes and applications?

Yes, the Bomb Shell testing machine is fully customizable with interchangeable fixtures, sealing heads, and test chambers to accommodate various calibers and geometries. It supports defence applications such as artillery shell testing, pressure vessel validation, and hydraulic actuator testing. Customization ensures compliance with MIL-STD-1522 and ADA approval requirements, enabling precise and repeatable testing across different product configurations.

What kind of data acquisition and reporting capabilities are available?

The system includes advanced data acquisition with real-time pressure monitoring, digital recording, and automated test report generation. It supports traceability required for MIL-STD-1522 compliance and ADA approval documentation. Test results can be exported to centralized databases or MES systems, enabling detailed analysis of hydraulic actuator testing and aerospace component validation. Custom reporting formats can also be configured based on client requirements.

What utilities and infrastructure are required for installation?

The machine typically requires a stable power supply, a hydraulic fluid system equipped with a hydraulic accumulator, compressed air (if applicable), and a reinforced foundation for high-pressure operations. Proper ventilation and safety zoning are recommended for defence environments. Installation is carried out in compliance with MIL-STD-1522 guidelines and ADA approval norms, ensuring safe operation for hydraulic actuator testing and bomb shell validation processes.

What is included in commissioning and training?

Commissioning includes installation, calibration, system validation, and operator training. The process ensures compliance with MIL-STD-1522 testing procedures and ADA approval requirements. Training covers system operation, safety protocols, maintenance, and data interpretation for hydraulic actuator testing and aerospace validation workflows. Documentation such as manuals, test procedures, and calibration certificates are provided for long-term operational support.

What after-sales support and maintenance services are available?

Comprehensive after-sales support includes preventive maintenance, spare parts supply, remote diagnostics, and on-site service. The system uses globally recognized components to ensure easy availability and long-term reliability. Support services are aligned with defence standards like MIL-STD-1522 and ADA approval requirements, ensuring uninterrupted operation for hydraulic actuator testing and high-pressure aerospace validation applications.

Bomb Shell
Hydraulic Pressure Testing Machine

Detailed Technical Brochure

How the Bomb Shell Works

Load & Position

Fill & Measure Cavity Volume

Seal & Pressurize

Measure Deformation & Record

Dewater, Stamp & Unload

Explore the Machine in 3D

Supported Shell Types

Watch the Bomb Shell in Action

Configure & Request a Quote

Select the Ammunition Types You Need to Test

Choose Your Production Capacity

Add Optional Features

Review Your Configuration & Request a Quote

Your Details

Detailed Model Comparison

Built for Defence-Grade Reliability

1800 Bar Structural Capacity

Siemens PLC + SCADA

1 Micron Deformation Sensing

Comprehensive Safety

Quick Changeover Tooling

Global Defence Standards

Common Specifications

Common Questions

Ready to Configure Your Bomb Shell?

Configuration Submitted!

Similar Products

Share This Page

Bomb ShellHydraulic Pressure Testing Machine

Detailed Technical Brochure

How the Bomb Shell Works

Load & Position

Fill & Measure Cavity Volume

Seal & Pressurize

Measure Deformation & Record

Dewater, Stamp & Unload

Explore the Machine in 3D

Supported Shell Types

Watch the Bomb Shell in Action

Configure & Request a Quote

Select the Ammunition Types You Need to Test

Choose Your Production Capacity

Add Optional Features

Review Your Configuration & Request a Quote

Your Details

Detailed Model Comparison

Built for Defence-Grade Reliability

1800 Bar Structural Capacity

Siemens PLC + SCADA

1 Micron Deformation Sensing

Comprehensive Safety

Quick Changeover Tooling

Global Defence Standards

Common Specifications

Common Questions

Ready to Configure Your Bomb Shell?

Configuration Submitted!

Similar Products

Share This Page

Bomb Shell
Hydraulic Pressure Testing Machine