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K922-1Mobile Rail Welding Machines
K922-1 is a high-force mobile flash-butt rail welding machine for 6,500–10,000 mm² rails. Its 1,200 ± 60 kN upsetting-force class, independent clamping pressure multiplication and 100 mm upsetting stroke are intended for demanding mainline and long rail-string welding applications.
Technical Specifications
Rail cross-section
6,500–10,000 mm²
Mains voltage
380 / 400 V
Frequency
50 Hz
Maximum secondary current
67 kA
Continuous secondary current
21.5 (22) kA
Power at 50% duty cycle
211 kVA
Rated upsetting force
1,200 ± 60 kN
Clamping force
2,900 ± 200 kN
Upsetting stroke
100 mm
Hydraulic pressure
210 bar
Welding head dimensions
1,895 х 1,060 х 1,300 mm
Welding head weight
3,450 kg
Maximum productivity
Up to 15 welds/h
Technology & System Architecture
K922-1 performs continuous or pulsed flash-butt welding. Its high-force mechanical and hydraulic architecture supports demanding welding programs and controlled upsetting of long rail strings.
Clamping & Alignment
Clamping cylinders use independent pressure multiplication to maintain high clamping force during upsetting. The horizontal clamping-cylinder arrangement supports stable force as the clamping jaws wear.
Removal of excess upset
Removal of excess upset with independent hydraulic cylinders removes flash immediately after welding around the rail profile. Extended cutting edges increase blade service life.
Control & Quality
Current integrated configurations use Siemens PLC and KZESO WeldReg functions for automatic cycle control, real-time process analysis, welding-parameter recording and digital weld records.
Cooling & Hydraulics
The machine operates at 210 bar hydraulic pressure. Complete-machine and integrated configurations include matched hydraulic pumping and closed cooling systems with process interlocks.
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 K922-1 designed for?
K922-1 is designed for high-force field flash-butt welding, including demanding continuous-welded-rail applications.
Can K922-1 weld long rail strings under tension?
Yes. Its 1,200 kN-class upsetting system and independent high-force clamping architecture are designed for this type of application.
Can K922-1 be containerised?
Yes. K922-1 can be supplied as the welding subsystem of a KZESO Containerised Rail Welding Solution.
Does the К922-1 enable rail welding using the "tension" method?
Yes, the machine provides the capability to perform rail welding using the "tension" method, which makes it possible to install continuous welded rail (CWR).
Does the machine allow the clamping and upsetting forces to be adjusted depending on whether welding is performed using the tensioning method or conventional joint welding?
Yes. Thanks to the installed regulating valve, the machine can adjust the clamping force depending on the requirements and conditions of the welding process.
What control and monitoring systems are used in the К922-1 ?
К922-1 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.
What is K922-1 designed for?
K922-1 is designed for high-force field flash-butt welding, including demanding continuous-welded-rail applications.
Can K922-1 weld long rail strings under tension?
Yes. Its 1,200 kN-class upsetting system and independent high-force clamping architecture are designed for this type of application.
Can K922-1 be containerised?
Yes. K922-1 can be supplied as the welding subsystem of a KZESO Containerised Rail Welding Solution.