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K1000Stationary Rail Welding Machines
K1000 is a stationary flash-butt rail welding machine for production welding of railway rails. It combines automatic rail centring, controlled welding and post-weld flash removal for integration into a rail-welding production line.
Technical Specifications
Weldable rail cross-section
5,000–10,000 mm²
Rated mains voltage
380 V
Mains frequency
50 ± 0.2 Hz
Short-circuit power
600 kVA
Maximum secondary current
84 kA
Rated continuous secondary current
19 kA
Power at 50% duty cycle
180 kVA
Maximum upsetting force
800 kN
Maximum clamping force
2,000 kN
Maximum upsetting speed
100 mm/s
Maximum hydraulic system pressure
20 MPa
Maximum productivity
up to 21 welds/h
Rail string length
up to 1,000 m
Pumping station
with redundant pumping unit
Cooling system
closed-loop
Technical Specifications
Weldable rail cross-section
5,000–10,000 mm²
Rated mains voltage
380 V
Mains frequency
50 ± 0.2 Hz
Short-circuit power
600 kVA
Maximum secondary current
84 kA
Rated continuous secondary current
19 kA
Power at 50% duty cycle
180 kVA
Maximum upsetting force
800 kN
Maximum clamping force
2,000 kN
Maximum upsetting speed
100 mm/s
Maximum hydraulic system pressure
20 MPa
Maximum productivity
up to 21 welds/h
Rail string length
up to 1,000 m
Pumping station
with redundant pumping unit
Cooling system
closed-loop
Technology & System ArchitectureK1000 performs stationary flash-butt welding under programmed process control for repeatable production welding.
Clamping & AlignmentAutomatic centring positions the rail ends before the welding cycle. Hydraulic clamping holds the rails through flashing and upsetting.
Removal of excess upsetRemoval of excess upset after welding as part of the production cycle.
Control & QualityWeldReg and Siemens PLC architecture are used for welding-program management, process control and welding-data functions in the approved configuration.
Cooling & HydraulicsMatched hydraulic and cooling systems are supplied according to the stationary production-line configuration.
Key Advantages
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 K1000 designed for?
K1000 is designed for high-productivity stationary flash-butt welding of rails. The machine provides accurate and stable welding parameters, making it well suited for production lines dedicated to manufacturing long welded rail strings.
What rail sizes can K1000 weld?
The standard range is 5,000–10,000 mm². Project-specific execution is available for other profiles up to 10,000 mm².
Can K1000 be integrated into a containerised system?
Yes, where required by the project architecture.
What ensures high-quality welded joints with the K1000?
The K1000 provides precise control of the key welding parameters, including current, flashing time, flashing and upset. Automated process control ensures consistent results when welding large numbers of rails and reduces the influence of human factors.
Why is the K1000 suitable for intensive operation?
The K1000 is designed for continuous operation in industrial production environments. It features powerful welding and hydraulic systems, a robust construction and the possibility of integrating a modern automatic control system. This allows the K1000 to be used for high-volume rail welding while maintaining stable productivity and consistent weld quality.
What is K1000 designed for?
K1000 is designed for high-productivity stationary flash-butt welding of rails. The machine provides accurate and stable welding parameters, making it well suited for production lines dedicated to manufacturing long welded rail strings.
What rail sizes can K1000 weld?
The standard range is 5,000–10,000 mm². Project-specific execution is available for other profiles up to 18,000 mm².
Can K1000 be integrated into a containerised system?
Yes, where required by the project architecture.
What ensures high-quality welded joints with the K1000?
The K1000 provides precise control of the key welding parameters, including current, flashing time, flashing and upset. Automated process control ensures consistent results when welding large numbers of rails and reduces the influence of human factors.
Why is the K1000 suitable for intensive operation?
The K1000 is designed for continuous operation in industrial production environments. It features powerful welding and hydraulic systems, a robust construction and the possibility of integrating a modern automatic control system. This allows the K1000 to be used for high-volume rail welding while maintaining stable productivity and consistent weld quality.