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 rail welding equipment type CR100 comes in a wide variety of configurations: FBW Equipment kits, FBW containers and FBW mobile machines.
For more details about our offers, do not hesitate to contact us!
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.
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).
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 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.
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.
| 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 |
