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K1067Mobile Rail Welding Machines
K1067 is a mobile flash-butt rail welding machine for continuous or pulsed flashing without rail-string tension. It is designed for 6,500–10,000 mm² rail cross-sections and is particularly suitable where available inter-rail clearance is limited, including railway and metro applications.
Technology & System Architecture
K1067 performs continuous or pulsed flash-butt welding without rail-string tension. The automatic cycle controls rail positioning, flashing and hydraulic upsetting, followed by immediate flash removal.
Clamping & Alignment
The welding head automatically positions the rails to the required geometry before welding. Hydraulic clamping and upsetting maintain rail position through the welding cycle.
Flash Removal
Flash is removed immediately after welding by the machine’s integrated flash-removal system.
Control & Quality
Siemens PLC controls the automatic welding cycle. KZESO WeldReg records welding parameters and results, visualises the process in real time and can create a digital record for each welded joint. Supported configurations can use GSM/4G for remote monitoring and diagnostics.
Cooling & Hydraulics
Welding transformers and current-carrying electrodes operate with a closed cooling circuit and controlled coolant temperature. The hydraulic system provides up to 21 MPa operating pressure.
Technical Specifications
Rail cross-section
6,400–10,000 mm²
Mains voltage
380 V (mains) /400 V (diesel-generator set)
Number of supply phases
2
Frequency
50 Hz
Continuous secondarycurrent
24 kA
Power at 50% duty cycle
182 kVA (min.)
Clamping and upsetting drive
Hydraulic
Maximum upsetting force
600 kN at 20 MPa
Maximum clamping force
1,500 kN at 20 MPa
Hydraulic pressure
20 MPa
Upsetting stroke
100 mm
Cooling water flow rate
max. 25 l/min at 0.15 MPa
Cooling water temperature
max. 30 °C
Welding head dimensions (L × W × H)
1,915 × 1,100 × 1,215 mm
Welding head weight
max. 3,300 kg
Ambient temperature
–20 °C to +40 °C
Altitude
up to 1,000 m
Ingress protection
IP44
Welding time for UIC60
90–180 s
Key Advantages
Available Configurations
Welding Head
Welding head with integrated welding transformers/current-carrying assemblies, hydraulic clamping and upsetting mechanisms, flash-removal mechanism where applicable, and machine-side sensors, valves, actuators and connection points required for integration.
Complete Welding Machine
Everything included in the Welding Head configuration, plus the matched hydraulic pumping station, control cabinet and welding-process control system, cooling equipment, interconnecting power/control cables, hydraulic and cooling hoses, and required auxiliary equipment.
Containerised Solution
Complete Welding Machine integrated into a project-specific transportable system with hydraulics, cooling, control equipment, autonomous power generation where required, welding-head handling equipment, container infrastructure and project-specific safety systems.
Frequently Asked Questions
What rail cross-sections can the K1067 weld?
The K1067 welding head is designed for flash-butt welding of rails with cross-sections from 6,400 to 10,000 mm², with flash removal directly after welding under field conditions.
How is the K1067 powered?
The head operates from 380 V mains or from a 400 V diesel-generator set, 50 Hz, with a two-phase connection. Power at 50% duty cycle is at least 182 kVA.
In what ambient conditions can the K1067 operate?
The K1067 is designed for ambient temperatures from –20 °C to +40 °C at altitudes up to 1,000 m, relative humidity up to 80% at 20 °C (100% at 25 °C), and an environment free of conductive dust and corrosive vapours. Live parts are protected to IP44.
What upsetting and clamping forces does the K1067 provide?
Clamping and upsetting are hydraulically driven. At 20 MPa the head develops a maximum upsetting force of 600 kN and a maximum clamping force of 1,500 kN.
What is the upsetting stroke of the K1067?
The maximum upsetting stroke is 100 mm.
What cooling does the K1067 require?
The head is water-cooled. Required cooling water flow is up to 25 l/min at 0.15 MPa, with cooling water temperature not exceeding 30 °C.
What are the dimensions and weight of the K1067 welding head?
The welding head measures 1,915 × 1,100 × 1,215 mm (L × W × H) and weighs no more than 3,300 kg.
What rail cross-sections can the K1067 weld?
The K1067 welding head is designed for flash-butt welding of rails with cross-sections from 6,400 to 10,000 mm², with flash removal directly after welding under field conditions.
How is the K1067 powered?
The head operates from 380 V mains or from a 400 V diesel-generator set, 50 Hz, with a two-phase connection. Power at 50% duty cycle is at least 182 kVA.
In what ambient conditions can the K1067 operate?
The K1067 is designed for ambient temperatures from –20 °C to +40 °C at altitudes up to 1,000 m, relative humidity up to 80% at 20 °C (100% at 25 °C), and an environment free of conductive dust and corrosive vapours. Live parts are protected to IP44.
What upsetting and clamping forces does the K1067 provide?
Clamping and upsetting are hydraulically driven. At 20 MPa the head develops a maximum upsetting force of 600 kN and a maximum clamping force of 1,500 kN.
What is the upsetting stroke of the K1067?
The maximum upsetting stroke is 100 mm.
What cooling does the K1067 require?
The head is water-cooled. Required cooling water flow is up to 25 l/min at 0.15 MPa, with cooling water temperature not exceeding 30 °C.
What are the dimensions and weight of the K1067 welding head?
The welding head measures 1,915 × 1,100 × 1,215 mm (L × W × H) and weighs no more than 3,300 kg.