Mechelonic Engineers manufactures and suppliers rail flash butt welding plant along with the ancillary equipment. The plant consists of pre-straightening press, rail top and bottom cleaners, the flash butt welder with weld data recorder, fume extractor, upset trimmer, mobile post-straightening press, finish grinders, etc. Other ancillary equipment such as, water coolers, water chiller, rail drive units, hoists, diesel generator sets etc. can also supplied.

The Rail Flash Butt Welder is a tunnel type machine with the rail passing through the longitudinal axis of the machine. The rails are clamped over two meters each, through multiple clamps on each rail, to ensure adequate clamping without indentation. The electrodes are independently activated and are retractable to protect them from rails during transit.

The Rail Flash Butt Welder is designed to weld rails with cross-sectional area upto 10,000 mm2 of grades specified by UIC code 860.

• The machine is rail mounted and can traverse by 500 mm to correctly centralize the welded panel in the machine. The machine is capable of welding more than 20 joints per hour, (actual welding time less than 100 seconds for UIC 60 type rail).
• Multiple clamps distribute clamping load to avoid indentation on rail.
• Electrodes are water-cooled and retract to enable free passage of rails.
• Chilled water prolongs life of electrodes.
• Electrodes are self-compensating for wear.
• Rail alignment and anti-twist devices are incorporated.
• Lifting rollers facilitate free movement of rail through machine.
• Entry chute guides free rail into machine without hindrance.
• Weld face adjustments for aligning running faces and gauge face.
• Upset forging force is distributed along the weld axis.
• Servo controlled platen has independent hydraulic power pack to seal out contamination.
• Welding current supplied to head and foot of rail for uniform current distribution.
• DC power packs give balanced loading and high power factor.
• Microprocessor based control for entire automatic sequence with necessary interlocks and feedback.
• Weld data recorder gives graphic display of key parameters for analysis.
• Weld joint data printout for weld joint record.
• Parameter trends displayed for welded joints for analysis and maintenance assistance.
• Fume extractor expels fumes and fine dust from weld zone.

Upset Trimmers:
The rail upset stripping machine is a mobile unit which is placed immediately after the welding machine. It is self powered and can be aligned with the weld to facilitate stripping when the material is still hot. The stripping tools retract for rail passage and are changed for different rail profiles.

Straightening Press:
(Pre-straightening & Post-straightening Presses) The presses are suitable for rail upto 170-mm flange and 190 mm height and rail upto 78-kg/m grade UIC-860 conforming to IRS sections. The presses are capable of straightening bends or kinks in both horizontal and vertical planes, which normally occur during handling and transportation or during flash butt welding of rails to form panels. The pre-straightening press is provided as a stationary press, whereas the post-straightening press is mobile. The mobile press is self-propelled for positioning on the rail panel to be straightened. It runs on a rail track, provided by the consignee.