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K900A-1MMobile Rail Welding Machines
K900 A-1 is a mobile flash-butt rail welding machine for field welding of rails with a cross-sectional area of 6,500–10,000 mm². It supports continuous and pulsed flashing and removes flash immediately after welding. The machine is intended for mobile rail-welding installations and can also be used in a stationary installation where required.
Technology & System Architecture
The machine performs flash-butt welding using continuous or pulsed flashing. Welding parameters are controlled through the machine control system, followed by hydraulic upsetting to form the welded joint.
Clamping & Alignment
Hydraulic clamping and upsetting are integrated into the welding head. The lever arrangement provides clamping and upsetting force while maintaining a compact mobile-machine architecture.
Removal of excess upset
Removal of excess upset immediately after welding by the integrated replaceable-blade deburring mechanism around the rail profile. Side-blade position can be adjusted for the required finished joint geometry.
Control & Quality
Siemens-based programmable control is used for welding-process control and machine monitoring. WeldReg functions can record welding parameters and maintain weld records in the approved configuration.
Cooling & Hydraulics
Closed-loop cooling protects the welding transformers and current-carrying assemblies. The complete-machine configuration includes the matched hydraulic pumping station and cooling equipment.
Technical Specifications
Rail cross-section
6,500–10,000 mm²
Mains voltage
380 / 400 V
Frequency
50 Hz
Maximum secondary current
63 kA
Continuous secondary current
22 kA
Short-circuit power
400 kVA
Power at 50% duty cycle
170 (150) kVA
Rated upsetting force
545 kN
Clamping force
1,400 kN
Upsetting stroke
100 mm
Hydraulic pressure
110–120 bar
Welding head lenght
1,700 mm
Welding head width
1,060 mm
Welding head height
1,300 mm
Welding head weight
2,600 kg
Maximum productivity
Up to 10 welds/h
Key Advantages
Available Configurations
Welding Head
Welding head with integrated welding transformers/current-carrying assemblies, hydraulic clamping and upsetting mechanisms, removal of excess upset 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 rails can K900 A-1 weld?
The standard documented range is 6,500–10,000 mm². Final profile compatibility is confirmed for the project tooling and welding program.
Does K900A-1M remove flash automatically?
Yes. Removal of excess upset immediately after welding).
Can K900 A-1M be supplied for customer integration?
Yes. The Welding Head configuration is intended for integration into a customer or KZESO mobile system.
Where can the K900A-1М be used?
The K900A-1 can be used both for stationary rail welding at production facilities and rail welding directly in the track. This makes the machine suitable for the production of long welded rail strings, rail repair and renewal, as well as welding rail joints directly on the railway track.
The versatility of the K900A-1М makes it a practical solution for railway companies and rail welding contractors requiring one machine for a wide range of flash-butt rail welding applications.What control and monitoring systems are used in the K900A-1М?
The K900A-1М is equipped with a modern control system based on a Siemens PLC and a hydraulic system using Bosch Rexroth components. This ensures precise control of the welding and hydraulic processes, reliable operation and high repeatability of welding cycles.
The machine is also equipped with a modern welding parameter monitoring and recording system. The main welding parameters are recorded during each welding cycle and can be used for subsequent analysis and quality control.
After welding, the system generates a welding report containing the recorded key welding parameters, a process graph and the final welding result, indicating whether the weld meets the specified requirements (OK / NOK).
This provides full traceability of the welding process and helps reduce the influence of operator-related factors on weld quality.Can the K900A-1 remove the welding flash in a single pass?
Yes. Thanks to the improved design and increased working stroke, the K900A-1 can remove the welding flash immediately after welding in a single pass, without repositioning the flash-removing mechanism.
This allows the flash to be removed across the entire width of the welded joint in one operation, reducing processing time and increasing productivity.
On previous-generation machines, flash removal required repositioning the working mechanism and performing the operation in several stages. The increased working stroke of the K900A-1 allows the entire operation to be completed in a single working cycle.
What rails can K900 A-1 weld?
The standard documented range is 6,500–10,000 mm². Final profile compatibility is confirmed for the project tooling and welding program.
Does K900 A-1 remove flash automatically?
Yes. The integrated flash-removal mechanism removes flash immediately after welding.
Can K900 A-1 be supplied for customer integration?
Yes. The Welding Head configuration is intended for integration into a customer or KZESO mobile system.
Where can the K900A-1М be used?
The K900A-1 can be used both for stationary rail welding at production facilities and rail welding directly in the track. This makes the machine suitable for the production of long welded rail strings, rail repair and renewal, as well as welding rail joints directly on the railway track.
The versatility of the K900A-1М makes it a practical solution for railway companies and rail welding contractors requiring one machine for a wide range of flash-butt rail welding applications.What control and monitoring systems are used in the K900A-1М?
The K900A-1М is equipped with a modern control system based on a Siemens PLC and a hydraulic system using Bosch Rexroth components. This ensures precise control of the welding and hydraulic processes, reliable operation and high repeatability of welding cycles.
The machine is also equipped with a modern welding parameter monitoring and recording system. The main welding parameters are recorded during each welding cycle and can be used for subsequent analysis and quality control.
After welding, the system generates a welding report containing the recorded key welding parameters, a process graph and the final welding result, indicating whether the weld meets the specified requirements (OK / NOK).
This provides full traceability of the welding process and helps reduce the influence of operator-related factors on weld quality.Can the K900A-1 remove the welding flash in a single pass?
Yes. Thanks to the improved design and increased working stroke, the K900A-1 can remove the welding flash immediately after welding in a single pass, without repositioning the flash-removing mechanism.
This allows the flash to be removed across the entire width of the welded joint in one operation, reducing processing time and increasing productivity.
On previous-generation machines, flash removal required repositioning the working mechanism and performing the operation in several stages. The increased working stroke of the K900A-1 allows the entire operation to be completed in a single working cycle.