Copper Band Press for Ammunition Shell, rated to 1000 tons.

1. Description & Mechanical Design

The equipment is a single Hydraulic Band Press with a rated capacity of 1000 tons — 12 × max. 83-tonne hydraulic cylinders for pressing — 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.

Press Structure & Operation

• 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.
• Cylinders are fabricated in one piece (no welding) and mounted on a one-piece structural frame with bolt connections; mounting surfaces are machined for square alignment as per machine tool standards.
• Hydraulic cylinders: quantity 12, piston diameter ≥200 mm, piston rod diameter ≥110 mm, wall thickness 75 mm, stroke 30–35 mm, spaced evenly at 30° intervals.
• The central pressing station moves vertically via a hydraulic (ejector) cylinder with an adjustable stroke of ~200 mm, positioning the body's groove and ejecting the finished body for manual unloading.

Cycle Operation

• Loading: the hollow cylindrical body with the pre-mounted band is manually loaded onto the central pressing station using an electrical hoist.
• Positioning: the station moves downward to align the body's groove with the 12 pressing jaws.
• Pressing: the 12 jaws concurrently move radially inward to grip and press the band into the groove, applying a predetermined dwell time.
• Retraction & indexing: after pressing, the jaws retract; for multiple pressings, an automatic indexing mechanism rotates the body (15°–90° steps, 1–11 indexings per cycle).
• Ejection: the central station moves upward to present the pressed body for manual unloading.

Production rate 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 & Hydraulic Power Pack

Electrical Power System & Panels

• Dedicated Power, Control, and Operator Panels in IP54-rated enclosures, fabricated from 14/16 SWG CRCA sheet and powder coated in pebble grey, with standard switchgear (MCCBs, isolators, LED indicators, panel lighting).
• Power distributed through copper bus-bars with a calibrated digital energy meter; surge protection on AC and 12/24 V DC control supplies; earthing via copper strips and designated terminals.

Hydraulic Power Pack

• Complete power pack with motors, hydraulic pumps, valves, heat exchanger, and connecting pipes; high-pressure reciprocating piston/plunger pumps mounted externally with positive suction.
• Minimum 1500 litres of hydraulic oil, with power baffle plates and heat exchanger to prevent overheating; metered cartridges for piston lubrication with a separate lubrication pump.
• Delivers consistent operating pressure (270 kg/cm² working, up to 300 kg/cm² maximum) to all 12 hydraulic cylinders for uniform force application.

Control System & PLC Integration

• A PLC (e.g. Siemens S7-300) controls the entire operation — horizontal strokes, dwell time, indexing (number and degree), and job counting — with additional I/O capacity for future expansion.
• Touch-screen HMI (minimum 10-inch colour display) provides graphical visualization and adjustment of ejector stroke, hydraulic pressure, dwell time, and indexing settings, with recipe save/recall and password-protected parameter changes.
• All electrical motors meet IE-3 efficiency with MPCB protection; junction boxes and cable trays for wiring management; SMPS unit for low-voltage power; PLC/HMI program backed up on removable media, with an industrial-grade diagnostics laptop supplied.

Safety & Interlock Systems

• Hardware limit switches (limit, proximity, reed types) prevent over-travel; an emergency stop button enables immediate shutdown.
• Designed for operation up to 50°C ambient with visual and audible fault alarms; online PLC access available for backup and diagnostics without password blocking.

3. Operating Parameters & Performance

• Radial force: adjustable from 250 to 1000 tons via digital HMI control.
• Operating pressure: 270 kg/cm² working, 300 kg/cm² maximum.
• Cylinder performance: all 12 cylinders operate synchronously with a 30–35 mm stroke for even force distribution.
• Ejector system: 5–20 tons upward, 5 tons downward, adjustable stroke up to 200 mm via HMI.
• Cycle time: total cycle time (including manual loading/unloading, each capped at 25 seconds) programmed not to exceed 144 seconds.
• Indexing: programmable in 15° increments (15°–90° per cycle), 1–11 indexings per pressing cycle; dwell time adjustable 0–15 seconds in 1-second increments.
• Power supply: three-phase 415 V ±10%, 50 Hz AC.

4. Optional Enhancements

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, with serial number traceability.

Conclusion

This 1000-ton Hydraulic Band Press delivers precision mounting of a copper or gilding metal band into the external groove of a hollow steel cylindrical body — combining a robust 12-cylinder radial mechanical design, a central pressing station with adjustable vertical movement, fully automated PLC/HMI cycle control, a comprehensive 1500-litre hydraulic power pack, and an advanced electrical system with dedicated safety interlocks, for reliable, repeatable ordnance production.