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This specification describes a self-contained fully enclosed, ready for service, in-track welding system. The system is designed for tunnel operation. The unit is designed to run with high flash point fluids and all cables and hoses are fitted with fire proof shields. The system is complete with a diesel engine generator set and integral cooling system. Voltage control is by means of direct control.
Hydraulic power is derived from a hydraulic pump driven from a 30kW electrical motor. The electrically driven pump provides power for both the welder and the crane. A 21 kW chiller, complete with circulating pumps, is provided to ensure the welding head operates within the correct temperature levels. This cooler is electrically driven from the generator secondary circuit.
All operating components are mounted on a steel base and are enclosed within a fire proof lined aluminum enclosure. Design of the enclosure and base allows the unit to be mounted from static plant welding or to be mounted directly on a truck chassis for mobile operations.
GT 100 Flash-Butt Welding Container
- Welding HeadGT100DR
- Shearing Knife
- Welding Electrodes
- Control and Power Cabinet
- Intensity (Weld process control and analysis software)
- Hydraulic Power Unit
- Cooling Unit
- Generating set
- Crane
- Weatherproof Container
- Accessories
Range of application | |
| Rail lengths, minimal | 1.5 m |
| Rail profiles: Standard rail profiles | 36 - 75 kg/m Vignole rail |
| Rail sections up to | 10.000 mm2 |
| Material identification | R220, R260, R260Mn, R350HT |
Production capacity (thermal capacity) | |
| For profile UIC 60, burr removal included | up to10 welds / h |
Ambient conditions | |
| Ambient temperature (operational) | 0°C to +50°C |
| Relative air humidity, max. | at 20°C max. 80 % |
GT100 Welding Head
Shearing Knife
Full profile shearing shall be achieved by passing the shear tooling across the weld immediately after the weld is made. The cutting edge is build-up by hard facing electrode for high temperature working conditions 850 °C.
WPC 2.0 (Welding Process Controller)
Welding Process Controller(WPC 2.0) is used for recording data during the welding operation of the Flash-Butt welding Machines, the data will be processed and displayed in real time under a simplified graphical on a touch screen display and stored on a flash memory card (CF) for further processing in a complex graphical on a personal computer (PC).
The Welding Process Controller(WPC) gives information about the following parametersof the welding process:
- the effective size of voltage in the welding transformer (V)
- the effective value of current in the welding transformer (kA)
- the forging force - the force of pressing together the rails to be weld (kN)
- the displacement of the welding jaws (mm)
- the time elapsed during the welding process (s)
- the temperature of the environment during the welding process (°C)
- the GPS position of the welding machine during the welding process
Hydraulic Power Unit
Cooling Unit
SCH-SG 21
A cooling unit is provided to ensure the welding head operating temperatures are maintained within pre-set limits.
This is the most economic configuration, which is obtained by calibrating the finned heat exchanger banks to allow proper operation of the refrigerator at external air temperatures not exceeding 55°C.
Generating Set
The engine complies with EU stage 3A emissionlegislation according to the Non Road Directive EU 97/68/EEC. The engine also complies with TA-luft -50% exhaust emission regulations.
The engine is equipped with catalyzer.
Crane
A self-contained articulating twin boom hydraulic crane is provided to handle the welding head.
The crane is designed for a lift capacity of 7,000 Kg at an outreach of 3.6 meters.
These are controlled electrically by the Remote Control and manual mode by using levers located on the top of crane.
--SPECIFIC SAFETY FEATURES--
Specific safety features on this machine comprise:
- Multiple fire extinguishers.
- Multiple shut downs located at each corner of the container, on the welding head, on the control panels and on the engine operating panel.
- Pump units have auto shut downs in the event of fluid loss.
- Ground fault detector complete with shut downs are fitted to the operating unit.
- All hoses (except on head) run in contained troughs.
- All hoses and cables around the welding area are protected with fireproof coatings.
The FBW Machine is designed so that in case of a breakdown occurs, with the aid of an external power source, it is possible to operate the welding head and the manipulator in the emergency mode in order to put the machine into the transportation position so that the machine can be towed to exit the main line.
--PACKAGING&SHIPPING--
1.1. Delivery Time (Ex Works)
- 6 months from the date of confirmation of the order and receiving the down payment.
1.2. Delivery Exclusions
Our obligations do not comprise:
- All equipment, machines and other goods and services, which are not explicitly mentioned in this quotation.
- Welding process homologation.
1.3. Provisions by the buyer
- Provision of rail material in good quality, 20 rail pieces at 1.6 meter long
- Availability of personnel for the operating and maintenance training in sufficient number and qualification.
1.4. Terms of Payment
% |
Rate |
Due date |
30% |
Down payment |
With the order immediately |
30% |
Progress payment |
Due at half delivery term |
30% |
Delivery payment |
Due before delivery |
10% |
Final Payment |
Due at commissioning on user site but not later than 3 months after delivery |
1.5. Warranty
- 12 months or 12.000 welds, whichever comes first.
The warranty is exclusive of parts subject to wear and tear.
--CONTACT US--
ADRESS: No.837 Xingshan Town, Economy & Technology Development Zone, Jinzhou ,Liaoning, China
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