Progress Rail Welding (PRW) offers several Containerized Rail Welding System’s one of which is the Model K950 Flash Butt system. This System is Self-contained and fully enclosed, shipped ready for service. The design of the enclosure and base provides for the unit to be mounted as a static plant welder or installed directly on a truck chassis (or flat wagon of a proper height) for mobile operation in-track.
Safety and operational reliability are design priorities for PRW equipment. The System operates with high flash point Hydraulic fluid, The Weldhead’s electrical cables and hoses are fitted with fire resistant shields and abrasion resistant covers.
Operating Power is furnish by an integrated diesel generator. Thermal heat rejection is design into the systems core providing a platform for worldwide operations in every railroad environment.
The K950 containerize system is equipped with a state of the art process controller. Attention to weld quality is addressed using preset parameters adapted to our
customer’s requirements. Operational control is provided by a HMI computer which also records and stores each weld’s certificate providing the customer with a permanent record of the quality of welds pro- duced by the system.
Electric motors supply hydraulic power for the weld head, crane and thermal rejection systems. Hydraulic oil filtration and waste heat rejection is incorporated in the system’s design. The Hydraulic system is monitored and controlled by the system’s programmable logic controller for optimal performance.
Excess electrical heat is expelled by a chiller system which transfers heat from electrical contact points in the weld head and electrical boxes to atmosphere using air over fluid radiators.
The System is provided with a dedicated purpose twin boom crane designed to work with the Model K950 Weld head. This rugged crane is used to lower, elevate, rotate and cradle the weld head when not in use.
K950 Weld head Specification and Features
Rail welding is carried out by utilizing the principle of flash resistance welding. The K950 machine can weld rails with a cross-section up to 12,000mm2. Integrated with the welding head is a flash removal device (Internal Shear).
Note: production rates dependent on site conditions rail geometry and preparation.
Up to 12 welds per hour (flash removal included) for regular process
Advantages of the K950
The Model K950 is designed to provide the highest standard of quality rail welds in- track. The Weld head is able of 120T of pulling force. The Model K950 completes a welding cycle from aligning to flash removal in one automatic sequence.
Hydraulic system of K950 is equipped with hydraulic accumulator that provides high upset velocity ensuring good weld quality on rails with high Si content.
The clamping cylinders of K950 are equipped with internal pressure intensifiers. This increases the mechanical clamp advantage to prevent slippage during welding process and ensure proper forging.
The automatic welding process is under the supervision of an Allan Bradley Programmable Logic Controller (PLC). This control system has been proven in more than 200 welding plants around the world. The PLC both monitors and controls current, voltage, pressure, and distance transducers mounted throughout the system. The PLC combined with the PRW Weld Monitoring Software, records the critical parameters and controls the welding process. This cutting edge system
of current and voltage feedback automatically compensate for deviations which occur during the welding process. This state of the art system is capable of storing a wide range of customer welding programs.
Progress Rail Containerized Rail Welder Model K950
DIESEL POWER STATION: 380V/50Hz (460V/60Hz)
RATED PRIMARY CURRENT (50% DUTY CYCLE): 540Amps
RATED POWER (50% DUTY CYCLE): 210KVA
RATED WORKING HYDRAULIC PRESSURE: 3200PSI
RATED UPSET FORCE: 1200KN (120000KGF)
RATED CLAMPING FORCES: 2900KN (290000KGF)
OVERALL DIMENSION (W*H*L): 1000x970x1895mm
PRODUCTION RATE: 12 / 18 WELDS / HR (flash/pulse)
The Progress Rail 250 Ton AC In-track Welder has a 110 Ton AC Weld Head and a fully automatic 160 Ton Puller. Learn more about our latest rail welding technology in the video.
International Sales Director
Director, International Business Development
Phone: +44 (0) 7966 337924
Infrastructure - Business Development Manager, Australia
Phone: +61 (0) 408 010 983
Progress Rail’s new fleet of 250-ton AC mobile welders have external pullers for closure welds, expanding our mobile offering of 180-ton fully integrated heads, extended boom units and excavator mounted welders.Learn More
Progress Rail Flash Butt Rail Welder ATMW Model K930 is a ready-for-service, in-track condition rail welding system. This System is primarily intended for use on rail infrastructure (construction and maintenance purposes), the machine is specifically designed and built as a mobile welding machine.Learn More
This System is Self-contained and fully enclosed, shipped ready for service. The design of the enclosure and base provides for the unit to be mounted as a static plant welder or installed directly on a truck chassis (or flat wagon of a proper height) for mobile operation in-track.Learn More
The Narrow Head Flash Butt Welder is tall and narrow, requiring only 8.5 inches of clearance from the adjacent rail or fixed object. This allows for completing a flash butt weld inside of a turnout in transit areas, where flash butt welds were impossible in the past and even thermite welds were difficult.Learn More