Development and manufacture of welding machines for flash-butt welding of rails
BAIDIN GmbH
AschaffenburgNew on Amplifa
About BAIDIN GmbH
BAIDIN GmbH, based in Aschaffenburg, develops and manufactures electric welding machines for flash-butt welding of rails. The portfolio includes mobile suspension machines for use directly on the track – including the B50AC (K355AM) machine for rail cross-sections of 6,500 to 10,000 mm² – as well as stationary systems for industrial production of long rails in welding plants. In addition to machine building, the company offers mobile rail welding under field conditions, including cutting to length, cleaning, welding and grinding of rail joints. Furthermore, K355-series rail welding machines are repaired and modernized, with worn components such as bronze guide bushings, copper bridges and hydraulic components being completely replaced. The scope of services also includes commissioning, adjustment of welding parameters, training of customer personnel and delivery of spare parts. The machines are used worldwide in the construction and maintenance of railway, subway and tram lines.
- Site
- Aschaffenburg
- Processes
- Electric flash-butt welding of rails (flash-butt welding, continuous and pulsed, Cutting rails to the desired length with strict squareness, Cleaning of the rail ends before welding, Grinding of the weld area (joint) over the entire circumference of the rails, Deburring immediately after welding (flash trimmer system with knives), Repair and modernization of K355-series suspension rail welding machines (replacement of, Development and manufacture of electric welding machines and spare parts for, Commissioning, technology maturing and optimization of welding parameters / training of
- Materials
- Rails R65, Rails R50, Rail steel (cross-section 6.500-10.000 mm2), Bronze (guide bushings), Copper (flexible bridges in the secondary circuit), Silver (coating of the auxiliary circuit elements), Rail steel R65/R50, Copper
- Certificates
- Warranty on rail welding work 5 years, Warranty on modernization 12 months
- Industries
- Railway construction, Subway/Metro, Tram construction, Track construction (new construction, reconstruction, maintenance)
- 01
Development and design of the welding machines
- 02
Manufacture of the machines and spare parts
- 03
Commissioning and adjustment of the welding parameters
- 04
Training of customer personnel
- 05
Services: rail welding, repair and modernization
Materials & Processes
Rail steel R65/R50
Rails of types R65 and R50 with cross-sections of 6,500 to 10,000 mm² are welded.
Copper
Flexible bridge material in the secondary circuit of the welding machines.
Bronze
Guide bushings in the housings of the welding head.
Silver (coating)
Coating of the elements of the auxiliary/secondary circuit to improve contact.
Sites
Aschaffenburg
DEAdministration and production site
- Materials
- Steel, copper, bronze
- Control cabinet with power section
- Pump station (15 MPa, 60 l/min)
- Water cooling unit
Products & Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Electric flash-butt welding of rails (flash-butt welding, continuous and pulsedJoining | – | – | – | – | Rails R65, Rails R50, Rail steel |
| Cutting rails to the desired length with strict squarenessMachining | Deviation from cutting squareness max. 2 mm | – | – | – | Rails |
| Cleaning of the rail ends before weldingSurface | – | – | – | – | Rails |
| Grinding of the weld area (joint) over the entire circumference of the railsSurface | – | – | – | – | Rails |
| Deburring immediately after welding (flash trimmer system with knives)Joining | – | – | – | – | Rails |
| Repair and modernization of K355-series suspension rail welding machines (replacement ofEngineering | – | – | – | – | Bronze, Copper, Silver (coating), Steel |
| Development and manufacture of electric welding machines and spare parts forEngineering | – | – | – | – | – |
| Commissioning, technology maturing and optimization of welding parameters / training ofEngineering | – | – | – | – | – |
10 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Suspension welding machine for flash-butt welding | BAIDIN GmbH B50AC (K355AM), type MSO-4501U1 | 30+ (in | Rail cross-section 6,500–10,000 mm2; max. upset value 15 mm; full travel 90 mm | – | Field conditions / directly on the track |
| Control cabinet with power section | BAIDIN GmbH | – | – | – | Aschaffenburg, Germany |
| Pump station (hydraulics, 15 MPa, 60 l/min) | BAIDIN GmbH | – | – | – | Aschaffenburg, Germany |
| Water cooling unit | BAIDIN GmbH | – | – | – | Aschaffenburg, Germany |
| Mobile rail welding complex (based on K355AM, with container, handling crane, | BAIDIN GmbH | – | Rail cross-section 6,500–10,000 mm2 | – | mobile / field conditions |
| Rail welding system B150DC (stationary) | BAIDIN GmbH B150DC | – | – | – | – |
| Rail welding machine B120AC (mobile) | BAIDIN GmbH B120AC | – | – | – | – |
| Welding machine B80AC | BAIDIN GmbH B80AC | – | – | – | – |
| Handling crane (crane manipulator) | – | – | – | – | – |
| Diesel power generating unit | – | – | – | – | – |
Additional services
Reference customers
Quality
The welding work is carried out in accordance with the standards of Russian Railways (STO RZD 1.08.002-2009, TU ZPT 80/350) and national or European standards. A five-year warranty applies to all welding work performed and a twelve-month warranty to modernization work.
| Evidence | Aschaffenburg |
|---|---|
| Warranty on rail welding work 5 years | |
| Warranty on modernization 12 months |
History
For more than 20 years, over 30 welding machines have been operated in eight countries; one machine in China has been in service for twelve years.
Flash-butt welding of subway rails during the extension of the 'Avtovodskaya' line in Nizhny Novgorod (R65 and R50 rails) according to STO RZD 1.08.002-2009 and TU ZPT 80/350.