Category: How to make a spot welder from a battery charger

How to make a spot welder from a battery charger

This project is an outline of how to build a resistance spot welder using salvaged parts from an old microwave. Lets get welding! The inside of the microwave is quite dangerous. The large capacitor maybe charged and can deliver a nasty or even fatal shock so ensure you discharge as soon as possible by touching a metal rod such as a screwdriver across the terminals to discharge it.

Okay so open up the microwave casing to reveal the electronic bits. Discharge that capacitor and get to work on removing the parts. You should find the transformer which should look very similar to the one in the photos.

how to make a spot welder from a battery charger

Remove the nuts and it should slide out pretty easily. I salvaged a few limit switches that we will use later and some of the cables are handy for power connections.

The fewer turns of wire increase the amps but lowers the voltage, and more turns increase volts while reducing the amps. Be careful not to damage the primary coil as we will be keeping this. The new winding will provide the current needed to weld stuff. By using really thick cable we can reduce the thousands of windings to a couple which will provide loads of amps.

The thick cable is needed as the resistance will cause it to heat up and melt the insulation if its too thin. Not good! The primary coil is put in first followed by the 2 shunts either side and finally the low gauge wire blue cable is wrapped a couple of turns.

4 cylinder diesel engines for sale

Remember to leave a decent length of cable that will attach to the welding electrodes. Our super high powered transformer is nearly complete. We just need to weld the top back on to seal it up. You could alternatively use 2 part epoxy to stick it on. Options are good, pick whichever one is easiest for you.

Jms578 vs asm1153e

We now need to attach our cable ends to the copper pins which we will use to weld. I machined some copper terminals but you could use some copper clamps from the hardware store. I designed and laser cut a simple MDF case for the arm which houses the switch for operation and holds the electrode terminals.Did you use this instructable in your classroom?

Add a Teacher Note to share how you incorporated it into your lesson. Have you seen the video above? If not, take a look now because it will help you as you go along in this instructable. Spot welders are used to fuse thin sheets of metal together. They are most likely used in the auto industry, as well as HVAC for welding metal ducting.

There are a couple of videos you should see before starting on this project, because you may want some background on how the device works.

This is roughly how it will look when it's assembled. A notch needs to be cut on one of the 2x2 arms, and you'll see what this is for later on. I found a piece of scrap can be used as a template. The notch can be cut out with a bandsaw, wood saw, or any other saw you can get creative with. I used a jig-saw, but wouldn't recommend it as the safest option.

The pieces get sanded, primed, and painted. I chose to paint this black and yellow. The lugs have a mechanism that can be tightened with a screwdriver to secure the connection with the wire. The tighter the better. Now that the wood is painted, finished, and dry I gave it about 2 daysthe unit can be assembled.

how to make a spot welder from a battery charger

The back panel is for a light switch and a power cord. Before screwing the panel into the base, make sure your cord goes in first.

The thick piece at the end of the cord prevents it from pulling back though the hole. This is also the time to add the 2 pieces of 2" x 2" x 4" support blocks to the base. Be sure of your measurements before you screw them down.

Mini Spot Welding Machine

You want them to end up flush with the side panels when it's done. Now it's time to wire up the electrical system. Starting with the power cord coming into the casing, I stripped the black wire, and attached it to the bottom terminal of the light switch.

Frigidaire manuals

Next, I attached one of the wires I had salvaged, to the right terminal on the transformer, stripped the other end, and attached that to the top of the light switch. The electrical could almost be finished here, but I wanted to add another switch, for safety and convenience, and that's where the salvaged switch from the microwave hack comes in.

The two wires attached to the switch can be wrapped with electrical tape to secure the connection and help insulate from electric shock. The both ends of the wires are stripped so the copper wire is exposed. One wire connects to the left terminal of the Metal Melte r's primary coil, and the other wire connects to the white wire on the power cable that runs back to the house. The electrical system is complete! The sides can be screwed on with 6 wood screws on each side. I used 2" wood screws after drilling pilot holes to make sure the wood didn't split.

The trigger switch is attached near the tip of the top welder arm, and at a bit of an angle so it can be pressed easily.Latest Projects Education. Power Electronics Making a battery spot welder. JavaScript is disabled. For a better experience, please enable JavaScript in your browser before proceeding. Making a battery spot welder. Thread starter Jon Sam Start date May 9, Search Forums New Posts. Hello everyone, I would like to build a small spot welder for lithium batteries cylindrical of course.

I don't want to use a microwave transformer because it is not practical, it is heavy and it does not serve any purpose just to weld plates on lithium batteries. Here, someone uses a capacitor of 2. Scroll to continue with content. MaxHeadRoom Joined Jul 18, 20, Sounds like a capacitive discharge stud welder. Usually a SCR is used to dump the charge.

how to make a spot welder from a battery charger

BR Joined Sep 22, 4, That looks cold to me. What's the resulting resistance? BR said:. KeepItSimpleStupid said:. I meant the joint looked cold.

Car-Battery Welding

Have you heard the term A cold joint? A cold solder joint?As part of an electric bike project I needed to weld 70 Li-Ion cells together. I could have just bought a battery welder but where's the fun in that? This is my build. Nothing complicated and it didn't need to last too long.

Did you use this instructable in your classroom? Add a Teacher Note to share how you incorporated it into your lesson. The timer relay can be set to be closed for 0. This in turn fires the starter solenoid, which allows current to flow down the electrodes, creating the weld. We could do without the timer relay and just control the weld by varying the time we press the button for but it gives a lot more control.

We don't want the battery floating around the workbench so we need to construct a solid base for it. Add some more 1" x 2" on the top of the enclosure we just made and cut a hole in it the same diameter as our firing button.

Wire everything together as shown in the previous wiring diagram and test fire it, making sure that both the relay and the solenoid fire as expected. We don't want the solenoid floating around so take some of the 10mm x 2mm steel bar and drill 2 holes in it.

This will serve as both the positive contact and a solid mount. Take two of the copper nails and cut the heads off them.

These will be inserted in to the choc-block to form the electrodes. Cut down some of the copper cable and mount some choc-block on the end. Insert the copper nails in to the other end and bend the wires until the electrodes are vertical and the wires are horizontal. Screw one wire to the -ve terminal of the battery and the other to the output of the starter solenoid.

You will need to experiment with how much pressure to apply to the electrodes but with a little practice you will be able to do a consistent weld.By using our site, you acknowledge that you have read and understand our Cookie PolicyPrivacy Policyand our Terms of Service.

Electrical Engineering Stack Exchange is a question and answer site for electronics and electrical engineering professionals, students, and enthusiasts. It only takes a minute to sign up. I saw in a lot of youtube videos people using capacitors connected in parallel to make use of the current for a spot welder for battery tabs, I was checking my cemetery box last night and found a lot like 60 Li ion C4 batteries, they are rated for mA and 4. I can also use them for other things, like a battery powered mini car for my kids, but what I need right now is a spot welder for fixing laptop batteries in my computer shop at the end of the world :I have no trouble charging them and I have been using batteries for a long time charging and discharging them with a constant current charger and limited voltage power supply, plus a temperature sensor, just in case.

Fixing batteries with a spotwelder is frequently done with large capacitor banks. The capacitorbank solves two problems at the same time. However when something goes wrong this battery would keep on supplying large currents. That would form a large risk in terms of fire hazard. For me is therefore a DONT.

Sign up to join this community. The best answers are voted up and rise to the top. Home Questions Tags Users Unanswered. Can I use a battery bank to make a spot welder? Ask Question. Asked 3 years, 6 months ago. Active 3 years, 5 months ago. Viewed times. I don't know that a battery than provide A? Safety requires some thought though, with more than one way to break the circuit if anything goes wrong. For comparison, I've tested a 90C turnigy nanotech li-po at A short circuit and that's about the size of just two cells.

Lithium batteries can supply ridiculous amounts of current for a few seconds - although it probably doesn't help their lifespan much though. It seems to work quite well: youtube. Is 4V enough? You might need to add an inductor in series. Active Oldest Votes. During spotwelding for fixing a battery cell a large to very large current is available. In case something goes wrong when fixing a battery cell the large current is reduced to low when the capacitors are discharged.

With a large battery made of Li-Ion cells you would be able to reach target 1. Decapod Decapod 3, 5 5 silver badges 19 19 bronze badges. Sign up or log in Sign up using Google. Sign up using Facebook. Sign up using Email and Password.

Post as a guest Name. Email Required, but never shown. The Overflow Blog. The Overflow How many jobs can be done at home?A fine-spot welder is one of the few equipment where building yourself is cheaper than buying. There are already published a lot of DIY spot welders, this one has some unique features: It can be used in 2 welding applications: opposed and series configuration. The construction is kept very simple.

Accurate electrode force adjustment. It has a solid electrode holder, made of a radiator earthing clamp. An Arduino microcontroller is used to set the weld time accurately. Creates a double pulse which improves clamping. The current can be reduced for welding sensitive parts. Did you use this instructable in your classroom? Add a Teacher Note to share how you incorporated it into your lesson. I purchased the new board it came with 7.

how to make a spot welder from a battery charger

I want to upgrade to the 7. I have it in arduino ide and have a usbasp 10 pin programer what is the pin out for the straight ftdi connector on the board? Reply 1 year ago. How do you calculate the resistance to reduce current. You cant use a resistor, just reduce the weld time or increase the weld pin force. Or use the new software version 7. A word of advise. Order his ATmega with his software already loaded on it.

If you a fairly competent with Arduino, you might bet a blank chip setup. If you are not good with Arduino, you definitely want to order his unless you are planning on using the Arduino UNO and just build the power supply section.Connect with us. Electronics Forums. Welder as battery charger??

DIY Battery Spot Welder!

Reply to Thread. Search Forums Recent Posts.

2008 saturn vue serpentine belt diagram

Scroll to continue with content. Aug 5, 1.

Status brom cmd fail

I beleve they are in series linked positive to negative series right??? There are two posts for each positive and negative so that there are four posts on each battery. There look to be a total of 18 cells, which would be 2V each. These are quite large. The problem that I have is my charger I bought with it is three phase label indicates that it is "cycle phase"??

I am thinking that if I were to use a 4 Volt inline resistor, and somewhere around amp it should charge the batteries quite well, although I am not an electronics expert of any sort and I really need some advice here as to what parts to use, how to wire this baby up and feedback as to just how crazy I might be.

Thanks in advance everyone, Cory Boehne. Aug 9, 2. Aug 9, 3. Aug 9, 4. Aug 10, 5. Aug 10, 6. I have seen the Lincoln MIG welder used as a battery recharger.

He was able to bring down the voltage to 14VDC and connected it up and ran back and plugged it in. Regretably he is related to me, my brother. He is alos not the brightest bulb in the bunch either, thank goodness. It was a battery from an old golfcart the U-Store-It dump outside the fence.

After seeing that I just never had the guts to try it myself. Aug 10, 7. It is possible to use a welder as a charger.

thoughts on “How to make a spot welder from a battery charger”

Leave a Reply

Your email address will not be published. Required fields are marked *