Hydraulic Rail Benders

Hydraulic rail benders are professional machines used in railway maintenance to correct rail deformation (such as bending, lateral bending, wavy wear, etc.), especially suitable for scenarios that require large correction forces. The following is a detailed introduction to hydraulic rail benders:

YZG Serie Hydraulic Turnout Rail Bender

YZG 500 Hydraulic Turnout Rail Bender Technical parameters:

YZG 530 Hydraulic Rail Bender Machine Technical parameters:

LZG 750 II Hydraulic Rail Bender Machine Technical parameters:

YZG 750 III Hydraulic Rail Bender Machine Technical parameters:

Rail Bender Structure and Working principle

The hydraulic rail bender consists of a lock hook assembly and a fuselage frame assembly, and the fuselage frame includes a cylinder assembly and a gap adjustment device.

• Oil cylinder assembly: includes oil cylinder, piston, sealing ring, top block, safety valve and oil return valve.
• Safety valve: factory preset, users are prohibited from adjusting it.
• Oil return valve: The opening and closing is achieved by controlling the steel ball through the screw. The spare oil return valve is only used when the main valve fails.
• Gap adjustment device: It consists of a top block, a handle and a limit screw, and uses the lever principle to achieve straightening or bending of the rail.

Hydraulic Rail Bender Structure

Hydraulic system

• Manual/electric pump station: Provides high-pressure oil power. Manual pumps are suitable for small-scale operations, while electric pumps are more efficient and suitable for frequent use.
• Cylinders and pistons: Convert hydraulic energy into mechanical thrust, usually made of high-strength alloy materials with strong pressure resistance.
• Oil pipes and joints: Connect the pump station and the cylinder, and must have pressure-resistant and explosion-proof properties to prevent oil leakage during operation.

Mechanical parts

• Fixed jaws and movable jaws: The inner side of the jaws has anti-slip teeth, which are suitable for different rail types (such as 43kg/m, 60kg/m, etc.) to ensure stable clamping.
• Support frame or base: Provides a reaction force fulcrum, and the design needs to adapt to the gap between the sleepers to avoid damage to the rail structure.
• Safety locking device: prevents the jaws from accidentally slipping during operation and improves operational safety.

How Does The Hydraulic Rail Bender Work

• Clamping and positioning
  Adjust the jaw position according to the deformation direction of the rail (horizontal or vertical). For example, when correcting the lateral bend, the jaws clamp the waist of the rail horizontally.
  Use the track gauge to measure the deformation, determine the correction range, and avoid overcorrection.
• Power output
  After starting the pump station, the oil pressure pushes the piston rod out, and the movable jaw applies thrust to the rail (common thrust range 50-200 tons).
  The oil pressure (usually 15-60MPa) is monitored in real time through the pressure gauge and converted into actual thrust to ensure precise control.
• Pressure maintenance and reset
  After the rail deformation is corrected, the pressure is maintained for 10-30 seconds to eliminate the elastic retraction of the material.
  Open the unloading valve, and the piston resets under the action of the spring or deadweight to prepare for the next operation.

Why Choose Hydraulic Rail Bender from AGICO

• High efficiency and labor saving
  Compared with traditional mechanical straight rail machines (such as bolt-top bar type), the hydraulic system can reduce manpower consumption by 70%, and can be operated by one person.
• Precise control
  Models equipped with digital pressure gauges or wireless sensors can provide real-time feedback on the correction force, with the error controlled within ±2%.
• Wide adaptability
  The modular design allows the replacement of different jaws, compatible with a variety of specifications from light rail (30kg/m) to heavy rail (75kg/m).
  Special models can withstand low temperatures of -40℃ or high desert temperatures.