Details

1. DESCRIPTION AND MECHANICAL DESIGN
1.1 Overview
 • Equipment: One Hydraulic Band Press with a rated capacity of 1000 tons ie. (12 X Max 83 Tonne Hydraulic Cylinder for pressing) 
 • Application: Designed for mounting an annealed copper or gilding metal band into the external circular groove of a hollow steel cylindrical body (positioned vertically on its base).

1.2 Press Structure and Operation
 • Pressing Mechanism:
   - The press is equipped with 12 hydraulic cylinders and pistons arranged radially in a single horizontal plane around a central pressing station.
   - Each cylinder drives a heavy-duty pressing jaw  and all 12 cylinders move synchronously to apply a uniform radial force into the groove.
   - The cylinders are fabricated in one piece (with no welding) and mounted on a one-piece structural frame using bolt connections for fine alignment. The mounting surfaces are machined to ensure square alignment as per machine tool standards.
 • Hydraulic Cylinder Specifications:
   - Quantity: 12
   - Piston Diameter: Minimum 200 mm
   - Piston Rod Diameter: Minimum 110 mm
   - Cylinder Wall Thickness: 75 mm
   - Stroke: 30–35 mm
   - Arrangement: Evenly spaced at 30° intervals around the central pressing station.
 • Central Pressing Station:
   - Located centrally among the 12 jaws, it moves vertically via a hydraulic (ejector) cylinder with an adjustable stroke of approximately 200 mm (adjustable via HMI).
   - The station positions the hollow body’s groove within the pressing zone and then ejects the finished body for manual unloading.                                                                                                           
 • Cycle Operation:
   1.  Loading: The hollow cylindrical body with the pre-mounted band is manually loaded onto the  central pressing station using an electrical hoist.
   2.  Positioning: The station moves downward to align the body’s groove with the 12 pressing jaws.
   3.  Pressing: The 12 jaws concurrently move radially inward to initially grip and then press the band into the groove, applying a predetermined dwell time.
   4.  Retraction & Indexing: After pressing, the jaws retract. If multiple pressings are required, an automatic indexing mechanism rotates the body (in programmable steps of 15° to 90° for 1 to 11 indexings per cycle) before subsequent pressings.
   5.  Ejection: The central station then moves upward to present the pressed body for manual unloading.
  
  Production Rate: The system is designed to achieve a minimum output of 20 band-pressed hollow bodies per hour, inclusive of manual loading and unloading (each not exceeding 25 seconds).

2. AUTOMATION, ELECTRICAL CONTROL, AND HYDRAULIC POWER PACK

2.1 Electrical Power System and Panels
 • Panels and Enclosures:
   - The press is equipped with dedicated Power, Control, and Operator Panels housed in IP54-rated enclosures, fabricated from 14/16 SWG CRCA sheet and powder coated in pebble gray.
   - Standard switchgear (e.g., MCCBs for incoming supply and motor feeders, isolators, LED indicators, and panel lighting) are integrated.
 • Power Distribution and Protection:
   - Power is distributed through copper bus-bars, and a calibrated digital energy meter is included.
   - A surge protection device is installed for both the AC and 12/24 V DC control supplies.
   - Proper earthing is ensured via copper strips and designated earth terminals.

2.2 Hydraulic Power Pack
 • System Overview:
   - The press is powered by a complete hydraulic power pack that includes motors, a set of hydraulic pumps, valves, a heat exchanger, and all necessary connecting pipes.

 • Key Specifications:
   - Pump Type: High-pressure pumps of reciprocating piston/plunger (piston pump) type.
   - Installation: Both primary and secondary pressure pumps are mounted externally on the power pack with positive suction.
   - Tank Volume: The system contains a minimum of 1500 liters of hydraulic oil, with provisions (power baffle plates and a heat exchanger) to prevent overheating.
   - Lubrication: Metered cartridges are provided for piston lubrication along with a separate lubrication pump.
 • Performance:
   - The power pack is designed to deliver consistent operating pressure (270 kg/cm² working, up to 300 kg/cm² maximum) to all 12 hydraulic cylinders, ensuring uniform force application during pressing.

2.3 Control System and PLC Integration
 • PLC-Based Control:
   - A PLC (e.g., Siemens S7-300) controls the entire operation, managing horizontal strokes, dwell time, indexing (both number and degree), and job counting.
   - The system is provisioned with additional I/O capacity for future expansion.
 • Human-Machine Interface (HMI):
   - A touch-screen HMI (minimum 10-inch color display) provides graphical visualization of process flows and allows adjustment of key parameters such as ejector stroke, hydraulic pressure, dwell time, and indexing settings.
   - The HMI supports recipe functions to save and recall settings and includes password protection for parameter changes.
 • Auxiliary Features:
   - All electrical motors (including those for indexing) meet IE-3 efficiency standards and have proper MPCB protection.
   - Junction boxes for control and power wiring are provided, with cable trays installed for proper cable management.
   - An SMPS unit supplies low-voltage power, and the final PLC/HMI program is backed up on removable media. An industrial-grade laptop is provided for diagnostics.

2.4 Safety and Interlock Systems
 • Interlocks:
   - Hardware limit switches (limit, proximity, and reed types) prevent over-travel and ensure safe operation.
   - An emergency stop button is incorporated in the control panel for immediate shutdown if necessary.
 • Environmental Monitoring: The system is designed for operation under ambient temperatures up to 50°C, with fault alarms (visual and audible) for abnormal conditions.
 • Backup: The system includes provisions for backup and diagnostics, with online PLC access available without password blocking.

3. OPERATING PARAMETERS AND PERFORMANCE

3.1 Force and Hydraulic Performance
 • Radial Force: Adjustable from 250 to 1000 tons via digital control on the HMI.
 • Operating Pressure: 270 kg/cm² working pressure with a maximum of 300 kg/cm².
 • Hydraulic Cylinder Performance: All 12 cylinders operate synchronously with a stroke of 30–35 mm to ensure even force distribution.
 • Ejector System: Capacity of 5 to 20 tons upward and 5 tons downward, with an adjustable stroke (up to 200 mm controlled via HMI).

3.2 Cycle Timing and Indexing
 • Cycle Time: Total cycle time (including manual loading and unloading, each capped at 25 seconds) is programmed to not exceed 144 seconds.

 • Indexing: Programmable indexing in increments of 15° (from 15° to 90° per cycle), with 1 to 11 indexings per pressing cycle.
 • Dwell Time: Adjustable dwell time per pressing from 0 to 15 seconds in 1-second increments.

3.3 Power Supply:
 • The system operates on a three-phase 415 V ±10%, 50 Hz AC supply.

4. SUMMARY
This technical offer describes a single 1000‐ton Hydraulic Band Press designed for precision mounting of a copper or gilding metal band into the external groove of a hollow steel cylindrical body. Key features include:
 • A robust mechanical design with 12 radially arranged hydraulic cylinders ensuring uniform, synchronous force application.
 • A central pressing station with adjustable vertical movement for precise positioning and ejection.
 • Fully automated cycle control with programmable indexing and dwell times, managed by a PLC and a 12-inch HMI.
 • A comprehensive hydraulic power pack delivering reliable high-pressure performance, with a minimum 1500-liter oil capacity, effective heat management, and integrated lubrication.
 • An advanced electrical system with dedicated panels, robust power distribution, and safety interlocks to ensure operational reliability and operator safety.

Some modern copper band press machines for ammunition manufacturing also include:
 • Rotary indexing tables (for continuous production)
 • Pre-heating stations (to slightly expand the copper band thermally before pressing)
 • Automatic shell recognition and program selection (via barcode/RFID)
 • Data logging for each shell pressed (serial number traceability)