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K1100Stationary Rail Welding Machines
K1100 is a modernised stationary rail-welding solution based on the K1000 concept. It is intended for specialised production tasks including alloy-steel rails and rail sections incorporating insulated joints.
Technical Specifications
Weldable rail cross-section
5,000–18,000 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
5,000–18,000 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 ArchitectureK1100 uses controlled stationary flash-butt welding. Welding programs and tooling are configured for the rail section and steel grade specified by the project.
Clamping & AlignmentThe centring and clamping arrangements are adapted to the specialised rail section being welded, including insulated-joint applications.
Removal of excess upsetRemoval of excess upset) equipment is adapted to the geometry of the specified rail section.
Control & QualityProgrammable control manages the welding cycle and machine systems. The final control and weld-data functions are defined in the approved K1100 configuration.
Cooling & HydraulicsHydraulic and cooling equipment is matched to the stationary machine and production-line requirements.
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 K1100 designed for?
K1100 is intended for specialised stationary rail-welding tasks, including alloy-steel rails and rail sections incorporating insulated joints.
How are tooling and alignment defined?
They are configured for the rail section and geometry specified by the project.
Can K1100 be containerised?
Yes, where the project requires a transportable stationary welding system.
What ensures high-quality welded joints with the K1100?
The K1100 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 K1100 suitable for intensive operation?
The K1100 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 K1100 to be used for high-volume rail welding while maintaining stable productivity and consistent weld quality.
What is K1100 designed for?
K1100 is intended for specialised stationary rail-welding tasks, including alloy-steel rails and rail sections incorporating insulated joints.
How are tooling and alignment defined?
They are configured for the rail section and geometry specified by the project.
Can K1100 be containerised?
Yes, where the project requires a transportable stationary welding system.
What ensures high-quality welded joints with the K1100?
The K1100 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 K1100 suitable for intensive operation?
The K1100 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 K1100 to be used for high-volume rail welding while maintaining stable productivity and consistent weld quality.