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K900TMobile Rail Welding Machines
K900T is a mobile flash-butt welding machine developed for tram rail profiles, including 59R1, 59R2, 60R1, 60R2. It is designed for field welding with continuous or pulsed flashing and immediate flash removal as part of mobile rail-welding equipment.
Technical Specifications
Rail profiles
59R1, 59R2, 60R1, 60R2
Rail cross-section
6,500–10,000 mm²
Mains voltage
380 / 400 V
Power supply phases
2
Auxiliary circuit phases
3
Frequency
50 Hz
Maximum secondary current
63 kA
Short-circuit power
400 kVA
Short-circuit resistance
105 µΩ
Rated primary current
395 A
Power at 50% duty cycle
150 kVA
Continuous secondary current
18 kA
Rated upsetting force
545 kN
Upsetting-cylinder stroke
100 mm
Hydraulic pressure
11 MPa
Machine dimensions, length
1,587 mm
Machine dimensions, width
1,007 mm
Machine dimensions, height
1,400 mm
Machine weight
≤2,750 kg
Technology & System Architecture
K900T performs flash-butt welding using continuous or pulsed flashing for rail cross-sections from 6,500 to 10,000 mm² in the specified tram-rail application.
Clamping & Alignment
The machine uses hydraulic clamping and upsetting. Its mechanical arrangement is designed for stable positioning of tram rails during the welding cycle and can operate on either side of the track.
Removal of excess upset
Removal of excess upset mechanism removes flash immediately after welding. The mechanism operates independently of the clamping cylinders, allowing deburring before the electrodes are opened.
Control & Quality
The welding cycle is controlled automatically by the machine control system. The delivered control architecture is configured for the approved tram-rail welding programs and machine monitoring.
Cooling & Hydraulics
A closed cooling system cools the welding transformers and current-carrying electrodes and provides coolant-temperature adjustment. Hydraulic system operating pressure is 11 MPa.
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 is K900T designed for?
K900T is designed for field flash-butt welding of tram rails, including 59R1, 59R2, 60R1, 60R2 profiles.
Can K900T work on both sides of the track?
Yes. The machine can operate on both the right-hand and left-hand rail.
How removal of excess upset?
Removal of excess upset immediately after welding and operates independently of the clamping cylinders.
What control and monitoring systems are used in the K900Т?
The K900Т 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 K900Т remove the welding flash in a single pass?
Yes. Thanks to the improved design and increased working stroke, the K900Т 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 K900 allows the entire operation to be completed in a single working cycle.
What is K900T designed for?
K900T is designed for field flash-butt welding of tram rails, including 59R1, 59R2, 60R1, 60R2 profiles.
Can K900T work on both sides of the track?
Yes. The machine can operate on both the right-hand and left-hand rail.
How removal of excess upset?
Removal of excess upset immediately after welding and operates independently of the clamping cylinders.
What control and monitoring systems are used in the K900Т?
The K900Т 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 K900Т remove the welding flash in a single pass?
Yes. Thanks to the improved design and increased working stroke, the K900Т 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 K900 allows the entire operation to be completed in a single working cycle.