Rail welding equipment type CR100

Rail welding equipment, type CR100

Contrail Machinery provides you with the rail welding equipment, type CR100, a high-performance machinery designed for flash-butt welding by pulse flashing of rails with a cross-section of 5.000 mm² to 12.000 mm². The CR100 welding head stands out for its versatility and reliability, ensuring seamless welding processes across a wide range of applications.

This equipment is specifically crafted to enhance efficiency and precision, making it an indispensable tool for both large-scale rail construction and routine maintenance projects.

As a state-of-the-art solution, the rail welding equipment type CR100 is specifically engineered to meet the rigorous demands of modern rail construction and maintenance projects. It combines advanced technology with robust construction to deliver exceptional results.

The rail welding equipment type CR100 comes in a wide variety of configurations: FBW Equipment kits, FBW containers, Flash-Butt Welding Machines and FBW mobile machines.

Its flexibility in configuration makes the rail welding equipment type CR100 suitable for diverse project requirements, ranging from mobile setups for remote locations to fully equipped containers for stationary operations

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Why choose the CR100 welding head?

The rail welding equipment, type CR100 ensures high efficiency and can be used in high-speed line projects that meet the most demanding requirements. Due to its excellent precision and durability, this flash-butt welding equipment guarantees superior weld quality, high productivity and alignment requirements.

The rail welding equipment type CR100 is also equipped with advanced automation features that simplify the welding process while maintaining consistent quality. This makes it an excellent choice for projects requiring high-speed and high-volume welding tasks.

Due to its compact and simple design, the CR100 welding head is extremely easy to operate and maintain, which facilitates and streamlines the flash butt welding process.

In addition to standard rails, grooved rails and crane rails can also be welded (electrodes and shearing dies will be designed accordingly).

With its ability to weld a wide variety of rail profiles, the rail welding equipment type CR100 ensures flexibility and cost-efficiency for operators working across different rail systems.

The CR100 welding head is engineered to perform consistently under various climatic conditions, from extreme heat to cold, ensuring reliable operation and weld quality in diverse geographical locations. This versatility makes the CR100 an ideal choice for projects in varying environments, enhancing its utility in global rail construction and maintenance projects.

Advantages of the rail welding equipment, type CR100

HIGH PRECISION

The automatic vertical alignment is very precise. It is obtained by lifting the rails with the hydraulic cylinders and they are aligned to the preset reference blocks.

The alignment of the 4 vertical reference blocks is done by a mechanical adjustment system, each incremental step ensures a precision movement of 0.1mm up or down.

The rail welding equipment type CR100 delivers consistent precision, reducing alignment errors and ensuring superior weld quality for long-term track stability.

DURABILITY

The optimized central shaft provides alignment stability and has an extended service life due to the high-quality material and innovative lubrication system. The central shaft is equipped with a cooling system to ensure thermal stability and achieve long bearing life.

Special attention is paid to the lubrication and sealing system, therefore double lip scrapers and a metal scraper are installed for 100% protection of sliding bearings.

The welding head jaws are optimized and tested to withstand long-term fatigue, the new design offers a firm clamping capability and a solid structure of the whole mechanism.

Engineered for durability, the rail welding equipment type CR100 is built to handle intensive use, minimizing maintenance downtime and extending operational life.

VERSATILITY

With the new type of electrode, rail welding equipment type CR100 is able to weld rails with different profiles only by simply replacing the contact pieces (inserts). Up to 3 types of rails can be welded with a single electrode block.

This versatility makes the rail welding equipment type CR100 an all-in-one solution for operators, reducing the need for multiple specialized machines and streamlining project execution.

Main specifications

Rated main voltage	400/480 V
Mains frequency	50/60 Hz
Maximum secondary current	67.5 kA
Power at DC = 50%:	357 kVA
Working hydraulic pressure	270 bar
Rated upsetting force:	1000 kN
Rated clamping force	2600 kN
Upsetting Cylinder Stroke	110 mm

Welding head weight	3800 kg
Rail lengths	min. 1,2 m – max. 1000 m
Rail profiles standard	Vignole 40-75 kg/m
Rail sections	up to 12.000 mm2
Welding grooved rail	YES
Material identification	R260, R260Mn, R350HT
Welding cycle duration	90-160 seconds
Production capacity	Up to 15 welds/h

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