Automatic line for the production of railroad screw or screw spike bolts for rail fastening type VOSSLOH W21, Vossloh W30 and others type

11.08.2026

Automatic line for the production of railroad screw or screw spike bolts for rail fastening type VOSSLOH W21, Vossloh W30 and others type

We design and produce automatic lines for the production of railroad screw fastening or screw spike bolts such as VOSSLOH W21, Vossloh W30 and others type as part of a cross-wedge rolling line WRL2509 with a flat rolling tool.

Automatic line for the production of track screw for rail fastening type VOSSLOH W21, Vossloh W30, screw spike bolts

 

Automation of production of railroad screw including for rail fastening type VOSSLOH W21, Vossloh W30 with a tetrahedral head, track screw or screw spike bolts. The proposed technology and a set of equipment allows you to organize an effective technological process for the production of screws for track rail fasteners from a metal bar to a finished product. The key feature of the proposed set of equipment is the use of a cross-wedge rolling line WRL2509 with a flat rolling tool for thread rolling, which allows forming threads with uniform filling of the tooth material without breaking the longitudinal fibers of the macrostructure. Compared to rolling threads with rolls, cross-wedge rolling with a flat tool provides a multiple increase in tool durability and precision of the thread pitch, as well as the manufacture and maintenance of tools does not require expensive equipment. The flat cross-wedge rolling technology will allow the track screw to be tested for bending without destroying the screw, and its strength characteristics are improved.

 Productivity of the product production line way railroad screws St 35, Ss 25, Ss35 and screw spike bolts

1. Production cycle of the rolling line is 5 sec or 12 pcs per minute.

Productivity by year.

12x60x24x25x12x0.8 ≈ (from 4147200 to 4,400,000 pcs.)

2. Rolling threads on 2 screws in one pass is impractical! Since during the subsequent stamping of the screw head, the geometric parameters of the thread are violated.

3. Since 2010, we have manufactured and put into operation 10 lines for the production of the product "Travel screw" according to the following technical process (see doc. technical process of screw production):

 

Technical process of screw production from the blank to the final product.

1. Cutting the workpiece from the bar or coil material with preliminary editing;

2. Loading the cut blanks into the slide hopper.

3. Rhythmic feeding of workpieces from the slide hopper to the inductor loading device.

4. Heating a part of the workpiece for subsequent stamping of the screw head;

5. Punching the head with a chip in the AMT Hydraulic Press (for tetrahedral heads of the St 35, Ss 25, Ss35 type of VOSSLOH W21, Vossloh W30 systems) or punching the hex head of the screw without a chip; It is possible to stamp the tetrahedral head of the St 35, Ss 25, Ss35 type of VOSSLOH W21, Vossloh W30 and screw spike bolts systems in two transitions with the receipt of a blank with a stamped head without a chip.

6. Cooling of stamped workpieces on the conveyor.

7. Loading of stamped workpieces into the pass-through inductor.

8. Heating a part of the workpiece for thread rolling on the cross-wedge rolling line WRL2509

9. Rolling on the control panel line of the thread on the workpiece with a stamped head;

10. Screw cooling;

11. Cutting the chip on the screw head (for tetrahedral heads of the St type

35, Ss 25, Ss35 (VOSSLOH W21, Vossloh W30). Unless a different manufacturing process or product is used.

 

The technology we use allows us to maintain the geometric parameters of each element of the track screw. A map of the screw process (for tetrahedral heads such as St 35, Ss 25, Ss35 of VOSSLOH W21, Vossloh W30 systems) is presented in the document Tex. screw production process. For a track screw with a hex head of the type, the head chip cutting stage is not required.

 

 

Required energy sources (electricity, air, water)

Installed capacity of the equipment

No. / Equipment/ quantity /power, kW

1 / Storage device /1 /1

2 / Feeding device/1 / 1.5

3 / Cutting blanks press/1 / 7,5

4 / Gate storage of workpieces/1 / 1.5

5 / Inductor loading device/1 / 0

6 / 120 kW induction heater (1 mod)/1 / 120

7 / Press loading and unloading device/2 / 5

8 / AMT hydraulic press (head stamping)/1 / 15

9 / Cooling conveyor/1 / 1.5

10 / Induction heater 160 kW (2 mod)/1 / 160

11 / Rolling machine (thread rolling)/ 1/90

12 / Conveyor/1 / 1.5

13 / Edging press loading device /1 / 2,5

14 / Hydraulic press edged AMT /1 / 12,5

TOTAL           15        419. 5

 

Three-phase AC network of 380 V and a frequency of 50 Hz or 480 V and a frequency of 60 Hz

• The pneumatic equipment of the equipment must be powered by a compressed air network with a pressure of 0.4...0.6 MPa and a flow rate of at least 30 m3 / h.
• Cooling of heated units and elements of the water line is forced by continuous water supply at a pressure of 0.2...0.4 MPa. The water cooling system must be sealed. The temperature of recycled water at the line inlet is no more than 25 0C. Water consumption is not less than 16 m3 / h.

The most heat-loaded units of the cross-wedge rolling line have a cooling system with recycled water. This ensures that the dimensions of the resulting screws remain stable during the entire working shift of the line.

 

Management system

• Control system based on Mitsubishi, Siemens, Allen Bradley controller .
• The control system, based on a programmable controller, allows the line to operate in setup and automatic modes with all settings displayed on the operator's panel, provide self-diagnostics and monitor the operation of all controlled elements of the line;
• The complex of equipment allows automating the production process of a track screw from a metal bar to the final product with a stamped head and rolled thread. 
• High degree of automation. Provides uninterrupted and stable operation of the line with full control of all parameters (including in the composition with an induction heater, control of the heating temperature of workpieces and rejection or feeding into the line, a system for cyclic feeding of workpieces from the slide hopper, rolling forgings and transfer to the next production stage); 

Durability of the wedge tool of the rolling machine

The durability of the tool depends on the level of requirements for the accuracy of rolled workpieces, the deformation temperature and the tool material. In addition, an important factor is the individuality of each enterprise in its approaches to operating rules. Therefore, the durability of each tool is specified as an average value. An indicator of durability is the number of rolled workpieces. In order to increase the accuracy rate, the tool is delivered heat-treated evenly throughout the entire volume. The dimensions of the tool contain repair allowances that allow you to make from 5 to 15 repairs by consistently reducing its height.

Forming elements of the rolling tool are made of steel used for the production of dies (P6M5,M2) with quenching in a vacuum furnace.

The average durability values achieved in practice are as follows: for products intended for subsequent stamping, the durability of 1,400,000 products is achieved. During trial operation, the durability can reach up to 2500,000 products.

 A single set of wedge tooling consists of upper and lower mounting plates with wedge elements installed on them. No complex equipment is required to manufacture or repair the wedge elements.

 Сonclusion

A horizontal forging machine can be used to increase the productivity of the screw head landing area. It is possible to use operators or robots for loading and unloading workpieces of the induction heating unit, presses, and operations of moving workpieces from post to post.

Before sending the complex of equipment, acceptance tests are carried out on our territory. The test material is provided by the Customer. Tested samples and material residues are usually shipped with the equipment

Start-up and adjustment works: preparation of a production site with a foundation for equipment with the supply of necessary communications in accordance with the drawings of the supply of communications and foundation plans provided by Amtingineering (Supplier), are carried out by the Customer. Prior to the arrival of AMTENGINEERING (Supplier) specialists for commissioning, equipment placement is performed by the Customer in accordance with the equipment location plan, and does not require the presence of Supplier specialists.  Connection, start-up, testing, delivery of equipment as part of the start-up process.

commissioning works are performed by the Supplier's specialists. At the time of commissioning, the Customer's specialists are trained to work on the equipment.

 Accompanying technical documentation

• Operation and Maintenance manual;
• General technical drawings (assembly drawings of the main groups);
• Electronic, electrical, hydraulic, and pneumatic circuits, and a list of spare parts.
• To avoid unauthorized changes to the software, the source code of the line management program is transferred after the end of the equipment warranty. Remote service support of the software is provided during the warranty period.

 

Aesthetic and ergonomic requirements

• The line equipment should be easy to operate and maintain.
• The operator's workplace should be located in an area that provides monitoring of the operation of the main components of the line;
• Frame RAL 5005 blue; removable covers: RAL7035 (grey). Enclosures of cabinets and electrical control panels: RAL7035 (grey) (not painted in other colors).  It is possible to paint the frame and protective screens (except for cabinets and control panels) in a different color (alternatively: the color of the frame and painted parts of the equipment is anthracitegray RAL 7016. The color of the moving parts and safety elements is bright orange (RAL 2008).
• The control system should consist of the following main components: programmable logic controller PLC; HMI operator panel. 

Operating mode: automatic and set-up

• Control of the line in automatic mode from the central control panel;
• Control of the line in the set-up mode from the set-up and central control panels;

If you are interested, we are waiting for your requests. We can offer you equipment suitable for your tasks and delivery times, which will allow you to expand the range of products.

 t. +375-17-500-31-13

f. +375-17-500-31-32

+375255001523 (Viber, Whatsapp)

amtengine@amtengine.com