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

Details

Introduction
Introducing our Bomb Shell Hydraulic Pressure Testing Machine Upto 1800 Bar—a cutting-edge, fully automated high-pressure testing system engineered to rigorously assess the integrity of hollow steel bodies including bomb shells, artillery components, and other high-pressure critical parts. This advanced equipment is designed to simulate extreme operating conditions, providing precise measurements of maximum expansion and permanent deformation, ensuring that every component meets stringent safety and performance standards. With a comprehensive suite of integrated systems—from robust mechanical design to sophisticated electrical controls and automated handling—this machine is the definitive solution for industries where reliability and precision are paramount.

Comprehensive System Overview
Purpose & Role
 • Safety & Quality Assurance:
Ensures that hollow steel bodies, including specialized bomb shells and artillery components, can reliably withstand internal pressures up to 1800 bar. The system rigorously tests each component to certify that it complies with the highest safety standards required in aerospace, defense, and industrial manufacturing.
 • Design Optimization & Data Analysis:
By capturing precise data on maximum expansion during pressure application and permanent deformation post-test, the machine aids engineers in refining design parameters and improving material performance. The extensive data logging and reporting capabilities facilitate trend analysis, quality assurance, and continuous product improvement.

Testing Capabilities
 • Hydraulic Pressure Range:
   - Standard operational pressure from 250 to 1200 kg/cm2, with specialized configurations extending capability to 1800 kg/cm2.

 • Dwell Time Customization:
   - Adjustable dwell time ranging from 5 to 20 seconds to simulate various operational conditions and meet specific testing protocols.

 • Pressure Application Accuracy:
   - Utilizes high-precision hydraulic pump systems and pressure intensifiers to achieve and maintain the required pressure levels accurately during the test cycle.

Structural and Mechanical Features
Robust Construction & Precision Engineering
 • Heavy-Duty Steel Framework:
   - The frame, columns, crown, and base are fabricated from high-grade structural steel conforming to IS: 2062-2011 standards. The structure is stress-relieved and
precision-machined to ensure that all mounting surfaces are perfectly aligned. This guarantees that moving components, such as the ram and sealing head, operate
with impeccable accuracy.
 • Key Structural Components:
   - Top Beam & Bottom Cross Beam/Base:
     ▪ The top beam supports the sealing-cum-testing cylinder, ensuring that the hollow body is correctly positioned for pressure application. The bottom cross beam incorporates the pressure cylinder, which drives the hydraulic system.

   - Chromium-Plated Sliding Parts:
     ▪ Critical moving components, including guide bars, piston rods, and safety door rollers, are chromium plated. This enhances wear resistance, minimizes friction, and ensures long-term operational reliability.

Conveyors & Automated Material Handling
 • Dual VFD Gear Motor Driven Conveyors:
   - In-Feed Conveyor:
     ▪ Delivers hollow bodies in a horizontal orientation to the testing station with precise positioning.
   - Out-Feed Conveyor:
     ▪ Efficiently removes tested components, streamlining the production flow.

 • Six-Axis Handling Robot Integration:
   - A high-performance, six-axis robot (selectable from industry leaders such as ABB, KUKA, or FANUC) is integrated into the system. It automates the entire component handling cycle by:
     ▪ Retrieving components from the in-feed conveyor.
     ▪ Accurately positioning each hollow body in a vertical orientation at the loading-cum-filling station.
     ▪ Transferring components seamlessly to the sealing-cum-testing station.
     ▪ Moving tested components to dewatering and out-feed zones.
   - The robot’s repeatability and collision avoidance features ensure that handling operations are performed safely and efficiently, with minimal downtime.

Component Accommodation & Testable Equipment
 • Versatile Component Handling:
   - Designed to handle heat-treated hollow steel bodies with nominal outside diameters from 100 to 200 mm and lengths from 400 to 1000 mm. The system supports
components weighing between 15 and 50 kg, with a handling capacity rated up to 100 kg.

 • Range of Testable Equipment:
   - Suitable for testing components defined by various drawing specifications (e.g., drawing no. SM-XXXX, no. XXXXX, and no. SM-XXX).
   - Capable of testing a broad spectrum of equipment, including:
     ▪ Bomb Shells & Artillery Components:
     ▪ Standard high explosive (HE) shells (e.g., 155mm, 120mm).
     ▪ Base bleed (BB) rounds.
     ▪ Rocket-assisted (RAP) munitions.
     ▪ Cluster munitions and cargo/submunition shells.
     ▪ Inert/dummy rounds for training and practice.
     ▪ Smoke/illumination munitions, thermobaric rounds, sensor-fuzed and guided munitions.
     ▪ Extended range artillery and naval gun shells.
     ▪ Custom components with non-standard geometries, enabling versatility across various defense and industrial applications.

Testing and Measurement Process
Sealing & Pressure Application
 • Automated Sealing Mechanism:
   - A dedicated sealing-cum-testing head automatically seals the open end of the hollow body. This ensures that the hydraulic pressure is applied exclusively to the
internal fluid, preventing any leaks and maintaining test accuracy.

 • High-Precision Pressure Generation:
   - The hydraulic system comprises a high-capacity pump that generates the required pressure, complemented by a hydraulic intensifier/pressure multiplier. This system
amplifies the hydraulic pressure by a factor of 4 to 6, ensuring that the desired test pressure is achieved and maintained consistently throughout the dwell time.

Advanced Measurement System
 • Automated Data Capture Process:
   - Pre-Test Measurement:
     ▪ The system captures the initial external dimensions of the component using high-resolution probes.
   - During Test Monitoring:
     ▪ Continuously records the maximum expansion of the component as the pressure is applied.
   - Post-Test Evaluation:
     ▪ Immediately measures the permanent deformation after the pressure is released.
 • Precision & Resolution:
   - Measurement probes (LVDT/infrared-based with non-contact or indirect probing) deliver a resolution of 1 micron, ensuring that even the smallest deformations are
detected.

 • Data Integration & Reporting:
   - Real-time data is displayed on a 10-inch HMI, and all measurements are stored digitally via an integrated industrial PC. The system supports detailed reporting,
including serial number tracking, job details, and shift-based logs, which are crucial for quality control and regulatory compliance.

Electrical Power, Control & Automation
Robust Electrical Infrastructure
 • Dedicated Power & Control Panels:
   - The equipment features IP54-rated power, control, and operator panels constructed from 14/16 SWG CRCA sheet with a peddle gray finish. These panels incorporate industry-standard components such as MCBs, MCCBs, isolators, LED indicators, and surge protection devices, ensuring reliable and safe operation.

 • Switchgear & Cabling:
   - All electrical connections are routed through copper bus-bars and secured via properly rated cables. The design adheres to stringent electrical standards, ensuring
consistent performance even under high load conditions.

Advanced Automation & Monitoring Systems
 • PLC & HMI Integration:
   - PLC:
     ▪ The machine is controlled by a Siemens S-7 1200 PLC, programmed using ladder logic. The PLC system features clearly defined interlocks, safety flags,
and an expanded I/O capacity to support future upgrades.

   - HMI:
     ▪ A user-friendly 10-inch color touchscreen displays dynamic process flow diagrams, real-time operational data, and recipe functions. The HMI also
enables remote monitoring and diagnostics, enhancing overall system manageability.
 • Digital & Analog Monitoring:
   - Integrated digital and analog pressure indicators, energy meters, and sensor networks (including limit, proximity, and reed switches) provide continuous
monitoring of all critical parameters. This ensures precise control over the test cycle and immediate detection of any anomalies.

Detailed Operational Sequence
1. Component Loading & Initial Handling:
   - Hollow bodies are manually loaded onto the in-feed conveyor in a horizontal orientation.
   - The six-axis handling robot retrieves each component and positions it vertically at the loading-cum-filling station, ensuring optimal alignment for testing.

2. Filling & Sealing:
   - The internal cavity of the hollow body is filled with a water-based emulsion mixed with a rust-inhibiting compound, tailored to the specific volume of the component.
   - The component is then transferred to the sealing-cum-testing station, where the sealing head automatically seals the open mouth, preparing it for pressure application.

3. Pressure Application & Data Acquisition:
   - The hydraulic system applies the preset pressure with precision, maintaining it for the designated dwell time.
   - During this period, the advanced measurement system continuously monitors and records the maximum expansion of the component.
   - Immediately after pressure release, the system measures the permanent deformation, capturing critical data for quality assessment.

4. Post-Test Handling & Dewatering:
   - The handling robot transfers the tested component to a dedicated dewatering station, where residual fluid is efficiently removed.
   - Finally, the component is placed on the out-feed conveyor, ready for further processing, inspection, or manual retrieval.

Production Efficiency:
 • High Throughput:
   - The fully automated process enables a production rate of up to 40 hollow bodies per hour, ensuring consistency and repeatability essential for mass production
environments.

Safety, Spares, and Support
Uncompromised Safety Features
 • Integrated Safety Systems:
   - Multiple safety interlocks, including automatic shutters, guards, and emergency push-buttons, are in place to protect both operators and equipment.
   - Audio-visual alarms alert operators if pressure does not build up to the required level or if any anomalies are detected during testing.

 • Sensor & Collision Protection:
   - Advanced safety sensors, limit switches, and collision detection systems (supported by both digital and mechanical backup sensors) ensure safe operation throughout
the entire test cycle.

Comprehensive Spares & Technical Support
 • Quality-Assured Components:

   - All critical components—seals, valves, non-return valves, hydraulic pumps, pipelines, and hoses—are sourced from reputed manufacturers to ensure durability and
reliable performance.
   - The system is supplied with two sets of spare seals and standard non-return valves, minimizing downtime during maintenance.

 • Extensive Documentation:
   - Five sets of comprehensive operation, maintenance, and safety manuals are provided. These manuals include detailed hydraulic circuit diagrams, dimensional drawings, and OEM part specifications.

 • Extended Service & Warranty:
   - Our service commitment includes long-term support and readily available spare parts to ensure continuous, trouble-free operation over the machine’s lifecycle.

Turnkey Solution & Customization
Complete Turnkey Offering
 • End-to-End Project Implementation:
   - Our turnkey service covers every stage—from initial design, engineering, and manufacturing to on-site erection, commissioning, and comprehensive operator training.
 • Rigorous Proving Trials:
   - Extensive production trials (with a minimum of 1000 components per type) are conducted to verify that all parameters—pressure accuracy, cycle time, and measurement precision—meet or exceed the required specifications before dispatch.

Customization & Flexibility
 • Quick Changeover & Adaptability:
   - The in-feed and out-feed conveyors are fitted with adjustable V-block fixtures, enabling rapid changeover to accommodate different sizes and types of hollow
bodies.

 • Configurable Software & Reporting Capabilities:
   - Customizable software on the integrated industrial PC allows operators to set up and manage multiple test recipes, monitor process parameters in real time, and
generate detailed reports (including serial numbers, job details, and shift logs). This ensures seamless integration into existing quality control systems and facilitates
regulatory compliance.

In Summary
The Bomb Shell Hydraulic Pressure Testing Machine Upto 1800 Bar is the ultimate solution for high-pressure testing of bomb shells, artillery components, and a wide range of hollow steel bodies. With an emphasis on precision, automation, and comprehensive data acquisition, every aspect of this machine—from its robust structural framework and advanced hydraulic system to its sophisticated measurement and control capabilities—has been meticulously engineered to deliver unmatched performance, reliability, and safety.
For additional technical specifications, further details on the testable equipment, or to arrange a live demonstration, please contact our expert team at contact@neometrixgroup.com or call +91-120-6524888.