The complex is designed for flash-butt welding of rails with cross section area 6500 to 10000 mm2 under field conditions during repair and construction of railway and tram tracks.

The base of the complex is VOLVO 8×2vehicle chassis equipped with rails with carriages, which provide for travelling along the railway track driven by friction of the truck wheels on the rails of 1520 mm or 1435 mm in width.

The car body contains an autonomous diesel generator unit, a welding machine K920-1 or K922-1, a pumping station, a control cabinet, a hydraulic-powered lifting device and auxiliary equipment.

Parameter name Rate
Electric power sourceautonomous diesel generator unit
Neutral point connection of diesel-generator unitinsulated neutral
Rated mains voltage, V400
Mains current frequency, Hz50
Power of diesel-generator unit, kVA350
Cross-section of the rails to be weld, mm26500 - 10000
Rated continuous secondary current, kA21,5
Maximum short-term capacity at welding rails Р65, welding/hour13
Oil pressure in hydraulic system, MPa21
Rated mode of operation DC, %50
Machine time for welding rails with cross-section P65, sec120 - 180
Lifting device capacity, kg4000
Angle of rotation of the lifting device in the horizontal plane, degree±18 (±45*)
Luffing of extending section of the hydraulic lifting device, mm0 - 860
Travel speed by rail, km/h40
Overall dimensions, mm:
length10000
width2550
height from the rail head3970
Total weight, kg28500±200
Movement method Railway track, highway

* Is supplied by custom order

Welding Machine

The basis of the complex is a mobile machine K922-1 designed for welding rails in the pulsed flashing mode.  The control system of the welding machine is built on the modern programmable logic controller by SIEMENS.  The welding machine is equipped with a computerized control system for welding modes and providing each welded joint with a data sheet.

Welding transformers of higher power are used in K922-1 machines, which allows welding in the more hard modes – higher welding current and welding voltage, ensuring the pulsed flashing mode, reducing the time and size of the rail warming zone near the joint, thereby ensuring high-quality welding of the rails of high-alloy steel.

The use of pulsed flashing makes it possible to reduce the time for heating the ends of the welded rails, and therefore significantly reduce the machine welding time up to 100 seconds, reduce the size of the rail metal melt down during welding up to 30 millimeters.  The increased machine power and the reduced machine welding time allowed increasing productivity, providing energy saving and welding of difficult-to-weld rails as well as applying new technologies in the construction and repair of the railway track.

The power supply of the complex is provided by an autonomous diesel-generator set built on the base of diesel produced by CUMMINS and a synchronous generator by STAMFORD.

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