Universal system welding of rails
Universal system of direct current flash butt welding of rails
The universal system for welding of rails is a welding machine (welding head B150DC) which is the basic executive component and can be a part, both suspended (fig. 1), and the stationary welding machine (fig. 2)
The welding machine B150DC as suspended modification is fixed on a hanger (fig. 1). Two rectifier assemblies are on this hanger too. To install the welding machine on rails, the load-lifting mechanism (crane-manipulator) is required.
The welding machine as fixed modification is placed on a bearing bed (fig. 2). Hydraulic devices only are fixed on the hanger. Two rectifier assemblies are below, near the bearing bed. Welding head is stationary, and rails come to a welding zone on roller conveyer (on rollers). The load-lifting mechanism for positioning of the welding head isn't required. This device is completely equivalent replacement for the stationary welding machine.
THIS IS THE IDEAL SOLUTION FOR WELDING OF ALL SIZES OF CRANE RAILS (UP TO CR175) - THE DISTANCE FROM THE POWER SOURCE (DIESEL-GENERATING SET) DOES NOT REDUCE THE POWER TRANSMITTED FROM THIS SET.
Advantages of the universal system of contact butt welding of rails
- Burn-off (welding) occurs by direct current (DC)
- Load of all three phases of a power line is distributed uniformly
- "Dips" of voltage in secondary circuit during welding are absent
- Heating of total cross section area of the welded rail is uniform
- The zone of thermal impact on a rail is small
- The guaranteed high stability of welding quality according to the European standard EN 14587-2
- Possibility of welding of rails made from steels of different grands
- High power factor
- Powerful performance
- Completely automated process of rails centering
- Completely automated process of welding
- Possibility to weld the long strings of welded rails direct on the way due to big travel (250 mm) of the welding machine mobile case (tightening of strings). It allows "to close", in turn, a gap between the ends of the welded rails without the additional pull mechanism.
- Completely automated and independent process of rag cutting (flash) without unclamping movement of both ends of the welded rails
- Normalization of a welding seam with compressed air after rag cutting
- Computer documenting (certification) of each welding seam (joint) with registration of all operational parameters
- The potential consumer doesn't need to get two welding machines (stationary and suspended). It is enough to have one welding machine with the corresponding options only and to use it as suspended or stationary. It gives essential saving of expense for rail-welding enterprises.
Any option gives better welded joint by higher efficiency and smaller energy consumption, than welding with alternating current.
|Power supply rated voltage (diesel-driven generator set), V||380|
|Power supply: rated frequency, Hz||50|
|Number of main phases||3|
|Rated primary circuit current, A||520|
|Rated secondary circuit current (DC), kA||21|
|Short-circuit current (DC), kA||60|
|Maximum upset force at a pressure in hydraulic system of 250 bar, kN||1500|
|Maximum cross section of welded rails, mm2||12000|
|Time needed for welding rails with cross section of 8,265 mm2, s||90-200|
|Clamping and upsetting devices||hydraulic-powered|
|Pressure in the hydraulic system, bar||100-250|
|Maximum clamping force at a pressure in hydraulic system of 250 bar, kN||4000|
|Upset value, mm, max.||20|
|Upset rate, mm/s, minimum||60|
|Flashing speed, mm/s||0,2-5,0|
|Total travel of welder, mm||250|
|Rated capacity at welding rails with cross section of 8,265 mm2, joints per hour||10|
|Welding rail length without using additional devices, m||1,2-1000|
|Cooling water flow at a pressure of 2,0 bar, l/min||60|
|Weight of welding head, kg, max.||4200|
|Dimensions of welding head:|