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K1100Stationary Rail Welding Machines
The K1100 is a high-productivity stationary flash-butt rail welding machine engineered for modern rail production facilities. It supports pulsed flashing, immediate deburring and welding of standard, head-hardened and high-alloy rails, including 350HT grade in the current configuration.
Designed for production of rail strings up to 1,000 metres, K1100 combines high welding output with automatic process control and digital weld monitoring. The current stationary offer specifies up to 21 welds per hour under optimal conditions and a fully automatic cycle covering pre-heating, alignment, flashing, upsetting and deburring.
Applications
High-volume stationary rail welding
Production of long rail strings up to 1,000 m
Standard, head-hardened and high-alloy rail welding
Rail welding plants and industrial production lines
Key Advantages
Technology & System Architecture
The stationary delivery set includes the K1100 welding machine with flash remover, pumping station, cooling unit, control cabinet, weld-parameter recording cabinet, cables and hoses, plus the warranty set of spare parts, tools and accessories. The hydraulic system uses a redundant pump-motor arrangement and monitoring features for stable operation. The cooling circuit is closed-loop and forced-circulation, with flow monitoring that blocks welding if circulation fails.
Control & Quality
A SIEMENS PLC-based control system automatically controls the welding process. WeldReg KZESO™ records process data, evaluates weld results, maintains weld logs and generates a digital record for each welded joint. The current offer also includes GSM-based remote monitoring capability and storage of welding programs for different rail types.
K1100 / Technical Specifications
Rated mains voltage
380 V
Frequency
50 ± 0.2 Hz
Short-circuit power
600 kVA
Maximum secondary current
≥ 84 kA
Rated continuous secondary current
19 kA
Welding power at DC=50%
180 kVA
Maximum upset force
800 kN
Maximum clamping force
2,000 kN
Maximum upset speed
100 mm/s
Maximum output
Up to 21 welds/h
Weldable cross-section
Up to 12,000 mm²
Available Configurations
Stationary Installation
K1100 welding machine with flash remover, pumping station, cooling unit, control cabinet, weld-parameter recording cabinet, connection cables / hoses and warranty tools / spares.
Containerised Solution
Three-container system: Container 1 - K1100 with finishing flash remover, pumping station, cooling post and flue-gas filtration; Container 2 - control cabinet, weld-recording cabinet, heating and air conditioning; Container 3 - diesel-generator, connection cables / hoses and warranty tools / spares.
Frequently Asked Questions
What rail grades can K1100 weld?
The current stationary offer states standard, head-hardened and high-alloy rails, including R220, R260, R260Mn and R350HT.
What is the maximum production output?
The current offer states up to 21 welds per hour under optimal conditions.
Does K1100 record welding data?
Yes. WeldReg KZESO™ records and evaluates welding parameters and maintains traceable weld records.
Is K1100 available as a containerised system?
Yes. The current containerised configuration is a three-container solution integrating welding, hydraulic, cooling, control, climate, power-generation and connection infrastructure.