RAIL GAS PRESSURE WELDING APPARATUS
Rails have been made longer to prevent
running noises, to improve riding comfort
and to reduce rail track maintenance cost
due to higher train speed.
Gas pressure welding is mostly
mechanically accomplished. Therefore,joining strength is even and highly reliable.
The same strength can be obtained byeither gas pressure welding or flash buttwelding.
In this welding method, on-track welding
as well as shop or field depot welding areavailable.
In this apparatus,following the guidance of
the RAILWAY TECHNICAL RESEARCHINSTITUTE, it was developed using thetechnology of Hakusan Co., Ltd. insulation
displacement machine, which is also activeoverseas.
By using semiautomatic type TGP - 8 type,
digital gas flow rate automatic control
device, Automatic swing device of heating
burner, quality is stabilized and reliability isincreased.

The photo shows
semiautomatic type TGP-8 type.

FeaturesThis apparatus is geared to obtain uniform weld quality. Because burrs are cut off throughextrusion while during high temperature right after gas pressure welding, when a defect suchas weld flaw occurs in the weld joint, it is opened during extrusion for trimming and thisis effective for quality control.
・Weld Strength and Hardness
Because heating temperature is controlled below the steel melting point and no filler metal is used,
weld strength is as high as that of the base metal.
The weld joint of the head hardened rail is softened due to welding heat.
However, a post – weld heat treatment device can be used to restore the hardness of the weldedpart as high as that of the base metal.

Please refer to page 8 for details.

・Workability
This apparatus is designed for compactness,lightweight and mobility to make on-track application
possible, not to speak of shops or field depot welding. Pressure welding efficiency with this apparatus
is remarkably high.
・Economy
Main consumables are oxygen, acetylene, fuel for the generator and grinding stones. Cost per
weld is far more economical than that of other welding methods even when amortization formachines and labor cost are considered.

Welding Method
Rail Gas Pressure Welding

Grinding of the rail end surface isnecessary for the rail gas pressurewelding.
After it squarely finishes it up witha special grinder, the cleaning agent
washes the worked surface.

The welding machine is set on therail, and the alignment checked of therail is can take place.
Next, the welding condition is to bechecked.

The welding machine pressurizes andheats

thebutting

partofallsurroundings with a special burnerby oxy-acetylene flames and bothrails are joined.

1Rail Gas Pressure Welding

After setting the trimmer,
extinguish the fire of the burnerand stop upsetting, release theclamp on the right side.

Hot shear removal of the burr of thewhole circumference with a trimmer.

After trimming, the welder has tocheck the crack at the joint point.
After grinding, penetrant test andmagnetic particle test are examined

2Post-Weld Heat Treatment

After the temperature of the rail
reaches 600℃ or less, the head of
the rail is heated with a specialburner.

The temperature of the rail head canreach 1000℃ if it is heated for 90
seconds.

Immediately after heating, it iscooled by a special blower down to300℃.

3ModelMain body & Operation unit
TGP －8－ B－ S2 － T①Product category
Category④Option

Rail size

CodeCategory※Code20kg/m～

5SNone-★Closure Weld Function

TCold district specification

CCode【T】& Code【C】

TC40kg/m40kg/m～

Manual560kg/m60kg/m～

5L★ Tensor required separately

70kg/m20kg/m～②Classification

8S③Operation

Category

CodeCategory※

Code

Light weight emphasis(3-Operation switch type

S1

Touchscreen typeS2shafts）

Rigidity emphasis (4B※It is selectable only when you select【8 S】【8】【8 L】 in ①Product category

Gas controller
Digital type display
特DGF －C徴

CodeManual flow adjustment

A

Manual flow adjustment& Built-in

Bbattery
Automatic flow adjustment※C※When [S2] is selected in ③ operation of the main,
automatic flow adjustment is possible.

Analog type display
MA-10255 ・・・・・Float type1

Hydraulic system diagram of Manual Type & Semi Auto Type

Manual Type【TGP-5Type】

Semi Auto Type【TGP-8Type】

Recommended Model of Main body & Operation unit

In case of 20kg/m～40kg/m rail
TGP －5S －－Manual type－・This is suitable when you want portability.

orTGP －8S －Semi Auto type－ S2 －・This is suitable when you want

In case of 40kg/m～60kg/m rail
Manual type

TGP －5－ B－－

・This is suitable when you want rigidity
and maintainability.

orTGP －

8

Semi Auto type－ S2 － T(C)－・This is suitable when you wantoperability.

In case of 60kg/m～70kg/m rail
Manual type

TGP －5L － B－

・This is suitable when you want rigidity－and maintainability.
・For large rail sizes, this type is suitable.

2Specification
Main body & Operation unit
Manual type

Model

Semi-Auto type

TGP-5

TGP-5-B

TGP-8-S2-T（C）

Clamping force

Max 230kN

Max 230kN

Max 230kN

Upset force

Max 330kN

Max 330kN

Max 330kN

Size (mm)L1,310×W550×H740

L1,380×W570×H775

L1,350×W570×H660

Main※Carrying

230kg

270kg

290kg

bodyWeight

Working

300kg

350kg

360kg

Appearance

Power supply

1.5kW, 200/220V, 50/60Hz, 3-phase

2kW, 200/220V60Hz,3-phase

Other than the above voltage can be manufactured. Please consult us.
Max. pressure
Hydraulic
pump

70MPa

70MPa

W600×D550×H850

W600×D550×H850

120kg

135kg

Manual operation of hydraulic changeover valve

Touchscreen operation

W725×D575×H700

W201×D97×H23065kg1kg

Size (mm)WeightAppearance

Operation
methodSize (mm)Operation

Weightunit
Appearance

Operating environment

Temperature: 0 ℃ (-10℃) to 40℃, humidity: 20 to 85% RH, but no condensation.
In ( ), cold district specification type：【TGP-8-S2-TC】
・Light weight type

Characteristic

・Rigidity type・Hydraulic operation is automatic・Replaceable consumable parts

・Welding record
・Automatic control of closure welding
・Hydraulic hose reduction※Carrying：at the carrying / without hydraulic equipments.
Working：at the working / with hydraulic equipments.

3DESIGN/PARTS may be changed without notice