Mobile Rail Welding System AMS200 for Closure Welds and Distressing

Nowadays, instead of producing continuous welded rails for new railway tracks, often only short sections of worn rails are replaced with new rail sections. This results in an increase in the number of closure welds, which consequently also increases the demand for distressing in one operation together with the welding process. Replacing only short rails even results in every second weld being a closure weld that requires distressing.

Mobile Rail Welding System AMS200

The AMS200 is the latest development in mobile rail welding machines, a new generation which enables the distressing and the flash butt welding process to be carried out in one operation, without an additional pulling device.

Mobile Rail Welding Systems

Mobile Rail Welding System AMS200 for closure welds and distressing

This welding machine features the necessary force to achieve the required calculated dilatation. The loss of material due to the welding process is taken into account in the calculation. The machine offers a long travel in order to allow a reliable distressing even at low temperatures.

The AMS200 has an integrated deburring unit independent from the moveable machine side which deburrs directly after welding while the rail ends remain firmly clamped. The distressing force acts in the neutral zone of the rail, which increases the weld quality and protects the machine from unwanted stress. Free space round the rail foot avoids collision with sleepers and track fasteners and minimizes the need to raise the rail ends.

Product Characteristics

  • Exact lateral alignment of the rail ends by means of an electronic measuring system with the possibility to check and adjust if necessary.
  • Prior to clamping, an integrated hydraulic lifting device presses both rail ends vertically to the crown stops for perfect alignment.
  • The excentric web clamping system is self-closing and increases the clamping force when welding force is applied.
  • The electrodes act in the web. They are actuated with separate hydraulic cylinders and are completely independent from the clamping system.
  • Force for distressing and welding: 1400 kN.
  • Total travel for distressing and welding: 300 mm.

System Types

The AMS200 is available in two system variants. The Supra Roadflex is a highly flexible truck-based system for road/rail operation. The Supra Multiflex system allows all the equipment to be incorporated into a compact and space-saving 30-foot container. As an alternative, there is also a system available whereby two 20-foot containers (the energy container and the welding container) comprise a single unit.

Original article © Schlatter Industries AG.


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Rail Welding Technology

Leading in stationary and mobile rail welding technology for more than 100 Years Schlatter is a market leader in stationary rail welding machines for long welded rail production (LWR) and for welding machines for turnout parts, frog points and crossings. The mobile rail welding systems are well known worldwide and widely used for welding continuous welded rails for high speed tracks and heavy haul tracks.

Rail Welding Machines

Focus on customer benefits with flash butt welding systems In Schlatter rail welding machines the focus is on quality. This comprises both: Quality, long life time and low operation costs of the machines but also quality of the final rail welds. For good quality welds, Schlatter developed the designated Schlatter Weld Processor (SWEP) which controls the main parameters 'current', 'force' and 'travel' and their correctly timed interaction. These three parameters are constantly supervised by the new Schlatter Weld Analyzer which records every weld. Setting tolerance fields allows deciding if the parameters are in the desired range immediately after the welding process. [gallery ids="16922,16921,16923"]

Mobile Rail Welding Machines and Systems

Schlatter offers various mobile rail welding machines and systems for in-track welding of continuous welded rails (CWR). The latest development produces closure welded tracks without separate pulling devices for distressing. Customers can choose between three different mobile rail welding machines: AMS200, AMS100 and AMS60. All these mobile welders offer the same high welding quality but different rail end aligning systems. AMS200 and AMS60 aligns on the running edge, left or right side selectable, and is most suitable for high speed railway tracks for passenger transportation. Furthermore the AMS200 has an autarkical deburring system, which allows to deburr the whole rail profile automatically directly after welding, even both rail end are in clamped position. The AMS100 aligns the centre of the web and is mainly designed for heavy haul and conventional railway tracks. Our AMS100 and AMS60 rail welding machines also have an incorporated deburring system which deburrs automatically, directly after welding around the complete rail profile. [gallery ids="16926,16920,16924"]

Truck or Container Based Rail Welding Systems

Two alternative rail welding systems are available: Supra Roadflex, the truck based system for road / rail operation with very high flexibility. Supra Multiflex, consisting of standardized containers which can be mounted onto flat wagons or can be used semi-stationary at the job site.

Stationary Rail Welding Machines and Systems

Welding short rails into long welded rails The renowned Schlatter rail welding machine GAAS80 is worldwide in daily welding operation in rail welding factories. It features DC weld current, precise alignment of the rail ends (on running edge, selectable left or right side), precise vertical alignment including 'crown-position', outstanding weld quality and automatic deburring only seconds after welding. The rail ends remain clamped during deburring which contributes to quality. Little remaining burr around the rail profile results in easy and cost effective grinding. For complete production lines, Schlatter cooperates with experienced partners for the additional machines like rail end brushing machines, straightening presses and rail profile grinding machines.

Flash Butt Welding Systems

Railway switches and crossings welded with Stationary flash butt welding systems The Schlatter GAA100 flash butt welding machine has an extremely compact housing, open at the front for easy loading and positioning of work pieces. There are four clamping presses in total, each with 1000kN clamping force, ensuring that there is no slip. Railway turnout parts, points and crossings as well as switch blades are exposed to very high loads. For a long service life, manufacturers use hard manganese and high alloy steel which is welded to conventional rail steel with the Schlatter GAA100. This requires complex weld programs and special processes. Major manufacturers of turnouts and switch blades use the Schlatter GAA100 successfully for its flexibility, its high quality welds and for its geometrical accuracy." ["post_title"]=> string(23) "Schlatter Industries AG" ["post_excerpt"]=> string(0) "" ["post_status"]=> string(7) "publish" ["comment_status"]=> string(6) "closed" ["ping_status"]=> string(6) "closed" ["post_password"]=> string(0) "" ["post_name"]=> string(31) "schlatter-rail-welding-machines" ["to_ping"]=> string(0) "" ["pinged"]=> string(0) "" ["post_modified"]=> string(19) "2019-10-25 15:40:20" ["post_modified_gmt"]=> string(19) "2019-10-25 14:40:20" ["post_content_filtered"]=> string(0) "" ["post_parent"]=> int(0) ["guid"]=> string(60) "" ["menu_order"]=> int(42) ["post_type"]=> string(9) "suppliers" ["post_mime_type"]=> string(0) "" ["comment_count"]=> string(1) "0" ["filter"]=> string(3) "raw" }