Thank you!
We will contact you shortly
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.
Applications
Heavy-duty mainline field welding
Construction and renewal of continuous welded rail
Long rail-string welding under tension using the machine’s own high-force clamping and upsetting architecture
Containerised and complete mobile road-rail welding systems
Key Advantages
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.
Flash Removal
An automatic throw-on flash remover 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.
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 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
2,043 × 1,032 × 1,303 mm
Welding head weight
3,500 kg
Maximum productivity
Up to 15 welds/h
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 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.