and we will get back to you.
Thank You!
Your enquiry has been received, We will get back to you shortly.
1. Introduction The Stun Shell Composition Filling & Assembling Machine is a pneumatically operated, fully automated solution engineered for the precision filling of pyrotechnic compositions into stun shells, followed by automated assembly, cleaning, labeling, and unloading. Designed with zero human intervention inside the hazardous zone, this machine is ideally suited for defense and paramilitary ordnance production, specifically to supply operational and training-grade non- lethal ammunition. Key use cases include: - Riot control ammunition - Non-lethal tactical diversion shells - Military simulation devices It is particularly developed for compliance with modern safety, traceability, and throughput expectations, all while operating under flame-proof, spark-proof, and moisture-controlled conditions. 2. System Architecture and Functional Overview The system consists of eight interlinked automation stations, each with dedicated hardware, sensors, and PLC-managed logic. The machine performs the following functions: 1. Shell feeding and alignment 2. Internal air-cleaning 3. Powder filling (41 ± 2 g of pyrotechnic composition) 4. Cap preparation: igniter insertion, rotation, epoxy dispensing 5. Cap tightening 6. Final shell cleaning 7. Labeling with QR/batch ID 8. Pick-and-place unloading into trays The entire process is tracked and recorded through a Mitsubishi iQ-F PLC system with 7” HMI. Fill weight and component torque values are digitally monitored and stored per batch. 3. Key Features Fully Automatic, Pneumatic Operation • Dedicated stations (1–8) perform each step—no manual handling of shells during manufacturing T-DAP-A3679-STUN SHELL .... High Throughput • Up to 500 shells per hour with digital counters and alarming for low hopper levels T-DAP-A3679-STUN SHELL .... Precision Filling • Powder-filling station accurately meters 41 ± 2 g of stun composition into each shell Cap Preparation & Assembly • Multi-step cap handling: feeding, igniter insertion (both sides), araldite dispensing, and final tightening on the composition-filled shell. Integrated Cleaning & Labeling • Shell cleaning (station 2), final surface wiping (station 6), and label application (station 7) ensure finished product quality. Automated Rejection • Defective caps or shells are automatically diverted to customer-supplied rejection bins PLC Control & HMI • Mitsubishi PLC with 7′′ HMI, programmable logic and real-time digital displays for fill quantity and count Safety & Certification • All pneumatic and electrical components are ATEX/Flame-proof certified; machine structure and wiring comply with ISI/Class standards 4. What It Does – Functional Overview This shell-centric line performs eight sequential operations without manual intervention: Shell Feeding & Orientation • Vibratory hoppers and servo-guided grippers pick individual empty shells, orient them correctly, and place them onto the main conveyor. Primary Cleaning • Retractable high-pressure air-knives scour internal and external surfaces, removing dust, oil, or residual debris to guarantee accurate fill weights. Powder Filling • A gravimetric metering module doses exactly 41 ± 2 g of stun composition (metal-based flash powder) into each shell body, using a high-resolution load cell and closed-loop feedback to maintain tolerance. Cap Sub-Assembly • In six micro-stations, caps are pre-prepared: feeders present cap halves, dual-axis pick-and-place robots insert igniters on both sides, and Araldite adhesive is dispensed in a controlled bead. Cap Tightening • A servo-torque tool secures each cap onto the filled shell at 2.5 Nm ± 0.1 Nm, with real-time monitoring to detect cross-threading or torque anomalies. Final Surface Treatment • Rotating brush modules and synchronized air jets wipe residual powder and adhesive burrs, ensuring a clean exterior for reliable labeling. Labeling & Serialization • Tamper-resistant, wrap-around labels with human-readable and QR-encoded batch data are printed on demand and applied with 4-axis contour tracking. Unloading & Reject Sorting • Finished shells are transferred by SCARA robot into collection bins, while any unit out of spec (weight, torque, label) is automatically diverted to a reject hopper with flagging for rework. 5. Detailed Station-wise Breakdown Station 1: Shell Feeding – Vibratory feeder with gripper mechanism places empty shells onto the conveyor. Station 2: Shell Cleaning – Dual-axis cylinder directs compressed air jets into the shell cavity. Station 3: Powder Filling – Uses high-precision gravimetric sensors; vibration-assisted hoppers prevent clogging. Stations 4.1–4.6: Cap Preparation – Includes feeding, dual igniter insertion, epoxy dispensing on threads, and transfer to main line. Rotary grippers and screwing motors used. Station 5: Cap Tightening – Servo-torque motor with 2.5 Nm ± 0.1 Nm setting; misaligned caps halted and flagged. Station 6: Final Cleaning – Two nylon-fiber rollers spin at 1,000 rpm to remove residue; final air-cleaning pass. Station 7: Labeling – Wrap-around sticker applicator includes QR/batch ID printing with integrated verification. Station 8: Unloading – SCARA pick-and-place arm transfers finished shells into designated trays. 6. PLC, HMI & Control Interface - Controller: Mitsubishi FX5U PLC with integrated motion control modules - HMI: 7′′ capacitive touchscreen; multi-language interface, password-protected recipe profiles I/O Points: • 128 Digital Inputs • 96 Digital Outputs Connectivity: • Ethernet/IP • RS-485 • CC-Link IE • OPC-UA (optional for MES integration) Logging: SD Card + USB export of: • fill weights • torque logs • reject reasons • maintenance alerts 7. Technical Specifications
