The complex is designed for flash-butt welding of rails with cross section area 6500 to 10000 mm2with burr removing immediately after welding under field conditions.

The base of the complex is DAF XF105.410 FAK 8×2 vehicle chassis equipped with railway hydrostatic carriage drive for travelling along the railway track 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.

The railway hydrostatic drive is presented in the following version:

  • The railway drives (carriages) in front and behind. The rear carriage rotates by 2 x 1000 to facilitate entry of the complex onto the rails within the railway crossings.
  • The drives are mounted on an integral additional frame in a special heavy-duty version for load distribution on the chassis of the car.
  • Two axles with a hydraulic drive, providing a large traction effort, with a wheel diameter of at least 410 mm.
  • The axle gearboxes or running axles are adjusted by special attenuators ensuring total travel and light wear.
  • The carriages are raised and lowered by hydraulic cylinders driven by a gear-type pump from the car engine’s power take-off box.
  • The drive is controlled through adjustment of pumps and motors via the joystick (control lever).
  • The car is raised when running on rails and the axles of the car are blocked by means of hydraulically-controlled brackets.
  • The minimum radius for travelling is possible by rotating both carriages.

The system of the railway drive is actuated hydrostatically.

The hydraulic piston pumps are actuated by an auxiliary drive from the car engine.  A closed hydraulic drive system is supplemented with various pressure reducing valves, hydraulic fluid reservoirs and coolers, pipes, etc.

The railway carriage has an axial drive directed at all four railway wheels.  The drive for the axle is equipped with a hydraulic servomotor, which is mounted inside the gear of the corresponding railway axis.

Technical characteristics of КСМ007

Parameter name Rate
Cross-section of the rails to be weld, mm26500-10000
Rated continuous secondary current, kA21,5
Rated mains voltage, V400
Mains current frequency, Hz50
Maximum capacity at welding rails with cross-section of 8200 mm2, joint/hour13
Oil pressure in hydraulic system, MPa21
Clamping force, kN (at hydraulic system pressure of 21 MPa)3000
Upset force, kN (at hydraulic system pressure of 21 MPa)1200
Rated mode of operation DC, %50
Machine time for welding rails with cross-section 8200mm2, sec180
Capacity of diesel generator unit, kVA400
Lifting capacity of crane-manipulator, kg4000
Angle of rotation of the lifting device in the horizontal plane, degree±45°/±18°
Luffing of extending section of the hydraulic lifting device, within, mm0-860
Travel speed of complex by road, km/h, at most80
Travel speed by rail, km/h, at most25
Minimum curve radius, m150
Overall dimensions of complex, mm:
length11020
width2500
height from the rail head3920
Weight, kg, at most 32000

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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