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 source | autonomous diesel generator unit |
| Neutral point connection of diesel-generator unit | insulated neutral |
| Rated mains voltage, V | 400 |
| Mains current frequency, Hz | 50 |
| Power of diesel-generator unit, kVA | 350 |
| Cross-section of the rails to be weld, mm2 | 6500 - 10000 |
| Rated continuous secondary current, kA | 21,5 |
| Maximum short-term capacity at welding rails Р65, welding/hour | 13 |
| Oil pressure in hydraulic system, MPa | 21 |
| Rated mode of operation DC, % | 50 |
| Machine time for welding rails with cross-section P65, sec | 120 - 180 |
| Lifting device capacity, kg | 4000 |
| Angle of rotation of the lifting device in the horizontal plane, degree | ±18 (±45*) |
| Luffing of extending section of the hydraulic lifting device, mm | 0 - 860 |
| Travel speed by rail, km/h | 40 |
| Overall dimensions, mm: | |
| length | 10000 |
| width | 2550 |
| height from the rail head | 3970 |
| Total weight, kg | 28500±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.