Real-Time Control System for Flash-Butt Rail Welding

The operational monitoring and control system was designed for the K-355ARM suspended rail-welding machine. The machine joins rails by continuous or pulsed flash-butt welding and trims the weld flash immediately after welding in field conditions.

Control and measurement

The system monitors the flash-butt welding process, quality-related parameters, actuators, discrete and analogue sensors, and the machine’s power circuits. It provides digital control in cycle, manual and setup modes, sets and regulates welding parameters, and controls the travel speed of the moving machine column during flashing.

Measurements include the effective current in the primary windings of the welding transformers, primary-circuit voltage, moving-column displacement and upset-cylinder pressure. The system calculates process and equipment-condition parameters and gives operators, welders, setup staff and technologists information about process repeatability and machine status.

Weld records and diagnostics

• Stores information about each welded joint;
• Creates and prints a record or “passport” for each joint in real time;
• Creates and prints a shift report at the end of the shift;
• Performs self-monitoring and self-diagnostics of the control equipment.