Railway rail welding equipment Custom FLASH Range

FLASH 1000 uses Flash-Butt Welding technology to create uniform, strong and repeatable joints between two rail segments.

During the process, the rail ends are clamped and aligned, then heated by the controlled passing of an electric current. Once the programmed parameters are reached, the rails are pressed towards each other with a force of up to 1,000 kN.

The process is managed automatically by dedicated software, which controls and records the voltage, welding current, displacement and applied force. The operator can follow the entire cycle from the control panel mounted on the equipment.

Advantages of the FLASH 1000 equipment

Automatic welding process
The welding cycle is controlled automatically, reducing the influence of manual intervention and ensuring the repeatability of the parameters for each joint.

High clamping and upsetting force
The system develops a maximum clamping force of 2,500 kN and an upsetting force of up to 1,000 kN, keeping the rails clamped throughout the process.

Integrated deburring
The excess material formed during welding is removed immediately after the joint is made, by the integrated deburring system.

Parameter monitoring
The equipment records in real time the voltage, welding current, displacement and force, providing traceability for every weld carried out.

Simplified operation
The automated process allows welding operations to be carried out by a single operator, via an ergonomic control panel.

Compatibility with several rail types
The system can be configured for Vignole rails, grooved rails used in tram networks and other railway profiles with a mass between 36 and 75 kg/m.

Rugged construction and precise control
FLASH 1000 is designed for intensive use within complex railway projects. The welding head has a mass of approximately 4,000 kg and a working stroke of 100 mm.

The clamping system keeps the rails in the correct position during the pulling, heating and pressing operations, reducing the risk of slipping. The equipment can pull rail bars up to approximately 500 metres long, the actual value being influenced by the conditions on site.

Control and traceability for every weld
The control software automatically manages the stages of the process and allows the parameters used for different rail types and profiles to be saved.

For each weld the following can be recorded and analysed:

• voltage;
• welding current;
• rail displacement;
• applied force;
• the evolution of the parameters throughout the cycle.

The recorded data can be used for quality verification, report generation and building a proprietary library of welding programs.