Rail Tensor

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Rail tensiometer (also known as a hydraulic rail stretching device or rail stress adjuster) is specialized equipment used in railway track laying and maintenance. Its core function is to apply controlled tension or stress adjustment to rails during operations such as stress relief of continuously welded rail (CWR) lines, long rail laying, rail welding, and routine maintenance. Through a hydraulic system, it stretches the rail to the designed length or to a zero-stress state corresponding to the locking rail temperature (stress-free temperature). This eliminates internal stress caused by temperature variations, prevents abnormal rail gaps, rail deformation, or rail breakage due to thermal expansion and contraction, and effectively enhances track structure stability and operational safety.

Our YLS-900 hydraulic rail tensiometer is suitable for stress relief of CWR lines, long rail laying, and on-site thermite rail welding. Within a certain range below the stress-free temperature, the equipment can forcibly stretch rails from a zero-stress state to the length required at the locking rail temperature, after which the rails are secured or welded. The equipment features a lightweight body, easy operation, and high pulling force. It is equipped with a hydraulic power unit (available with either a diesel engine or an electric pump), hydraulic cylinders, rail clamping devices, connecting rods, and high-pressure hoses. The clamping device adopts a wedge-type rail web gripping design, which automatically increases clamping force as the tensile load rises. It does not contact the rail head surface, thereby avoiding damage to the rail.

As a leading manufacturer of railway maintenance machinery, we are committed to providing efficient and reliable technical solutions for railway construction and maintenance. AGICO Rail offers professional hydraulic rail tensiometers and various other types of track maintenance equipment, including rail grinding machines, track lifting and lining machines, rail cutting machines, rail drilling machines, and tamping machines. If you are interested in our tensiometers, we are pleased to provide detailed technical information, equipment demonstrations, and even arrange on-site trials.

AGICO Hydraulic Rail Tensor Models

YLS-900 Hydraulic Rail Tensor

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Application: Designed for critical long rail stress management, this tensor is suitable for rail sections from 43 kg/m to 75 kg/m. It is primarily used for stress relief operations and the installation of Continuous Welded Rail (CWR), ensuring track stability and safety by compensating for temperature-induced stresses.

Key Features & Benefits:

• High Power & Precision: Delivers a maximum tensile force of 900 kN with a working stroke of ≥760 mm, enabling precise rail stretching. Equipped with a high-precision pressure sensor and intelligent control system for accurate prestressing control.
• Secure & Non-Destructive Clamping: Features a wedge-type web clamping mechanism with a self-locking function—the clamping force increases proportionally with the pulling force. All operations are conducted above the sleeper bolts, ensuring no damage to the rail head or track fasteners.
• Efficient & Operator-Friendly: Combines a lightweight design with easy operation. Its large pulling strength and efficient workflow make it ideal for creating a safe, stress-neutral rail surface for train operations, effectively preventing track expansion or breakage.

YLS-900I Hydraulic Rail Tensor

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Application: As an upgraded and more powerful model, this rail tensor is suitable for stress relief and long rail laying operations on standard rail sections from 43 kg/m to 75 kg/m (including 60 kg/m and 75 kg/m rails).

Key Features & Benefits:

• Enhanced Power & Extended Range: Builds upon the original YLS-900 design with a larger pulling force and a longer stretching working range, providing superior capability for demanding rail stressing and adjustment tasks.
• Durable & Customizable: Constructed with a high-strength alloy steel body for enhanced durability. It supports customizable technical parameters to meet specific project requirements.
• Efficient & Versatile Operation: Features a secure clamping device mounted on the upper side of the rail head, eliminating the need for ballast cleaning prior to operation. It offers dual functionality (both pulling and pushing), making it highly adaptable for various scenarios. The light body design ensures simple and efficient operation.

YFT-400 Hydraulic Rail Tensor

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Application: Suitable for adjusting rail gaps on various rail specifications, including 50 kg/m, 60 kg/m, and 75 kg/m rails.

Key Features & Benefits:

• Efficient Gap Adjustment: Delivers a maximum thrust of 400 kN. Its wedge clamping mechanism combined with a lever linkage system enables efficient and powerful pulling of rails to adjust gaps.
• Easy & Flexible Operation: Designed for easy operation and high efficiency. The hydraulic pumping station is available in both manual and electric versions, offering flexibility for different job site conditions.
• Safe & Reliable: Features an anti-locking function to ensure safe and reliable operation during the tensioning process.

YFT-400II Hydraulic Rail Tensor

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Application: This versatile tensor is designed for adjusting rail gaps on various types of rails, including common specifications such as 50 kg/m, 60 kg/m, and 75 kg/m.

 

Key Features & Benefits:

• Integrated Push & Pull Functionality: Combines both pushing (to widen) and pulling (to narrow) capabilities in one machine, providing a comprehensive solution for precise rail gap adjustment.
• Efficient & Powerful Operation: Engineered for high work efficiency, allowing for quick and effective modification of rail gaps.
• Safe & User-Friendly: Features a lightweight design and simple operation. The integrated anti-blocking function ensures safe and reliable use during all tensioning tasks.

AGICO Rail Tensor Advantages

Our design philosophy is Robust, Precise, User-Friendly.

Powerful Symmetrical Pulling System

Features a dual-hydraulic cylinder synchronous drive design, ensuring the pulling force is strictly perpendicular to the rail axis and synchronized on both sides, preventing rail twist or rollover.

Core pulling force range covers mainstream demands, offering models from 500kN to 800kN and even higher capacities, easily meeting the stretching requirements for 60kg/m, 75kg/m (UIC/CHN), and various heavy rails.

High-Precision Control & Measurement

Dual-Mode Control: Provides both force display (via high-precision hydraulic pressure gauge) and displacement display (via clear mechanical scale or optional digital displacement sensor), allowing operators to perform dual verification against design parameters.

Precise Execution: Enables millimeter-level control of elongation, ensuring minimal error in the achieved stress-free temperature.

Reliable and Sturdy Clamping Mechanism

Specially designed alloy steel clamping jaws, heat-treated for high hardness and wear resistance.

Self-locking or mechanical locking design absolutely prevents jaw slippage during stretching and pressure holding, ensuring operational safety.

Modular & Ergonomic Design

Quick Installation: Compact equipment structure with easy module connection allows for rapid positioning on the track.

Flexible Power Options: Choice of electric motor unit (for sites with power) or diesel engine unit (for field operations without power) based on site conditions.

Sturdy Frame: Overall steel structure optimized via FEA, offering high rigidity and stable load-bearing, equipped with wheels for short-distance movement.

Comprehensive Safety Protection

Hydraulic system integrates safety relief valves to prevent overpressure.

Equipped with pressure holding valves to maintain cylinder pressure for extended periods in case of pump stoppage or accidental line issues, providing ample time for locking operations.

Application

The AGICO Rail Tensor is a powerful assistant for the following critical operations:

• Long Rail Installation on New Lines: Final stress release and locking after the welding of rail strings to establish the designed initial stress state.
• Stress Adjustment on Existing Lines: Periodic re-release and adjustment of stress for sections with uneven stress distribution or "stress peaks" caused by seasonal changes.
• Rail Replacement Work: Precisely matching the stress state between new and existing rails when inserting new rails or replacing damaged ones.
• Track Major & Intermediate Maintenance Projects: Coordinating with operations like sleeper replacement and tamping to comprehensively restore track geometry and stress state.

Operational Safety & Maintenance

AGICO is committed to providing safe products and services. We provide a detailed Chinese/English Operation & Maintenance Manual with each unit. Key points include:

• Operators must be trained and familiar with hydraulic principles and equipment procedures.
• Pre-operation routine checks: Hydraulic oil, hoses, clamps, fastener conditions.
• Strictly prohibit any maintenance or loosening of connections under pressure.
• Regular maintenance schedule: Includes changing hydraulic oil and filters, inspecting seals, lubricating moving parts, etc.

Why Choose AGICO?

• Engineering DNA: We deeply understand the on-site challenges of railway construction; our equipment design stems from practice.
• Quality Commitment: A strict quality control system from raw materials to finished products ensures reliability and durability.
• Global Service Network: We provide timely technical support, operator training, and spare parts supply.
• Solution-Oriented: Beyond selling equipment, we are willing to share professional expertise in CWR stress management.