A welding machine is highly specialized equipment, but almost every man more than once in his life had to look for a similar unit for repair home appliances or car. It is easy enough to make a welding machine with your own hands, but it should be understood that the equipment is suitable for working on small structures. This will be arc welding from an AC or DC source.
Argon and gas welding require special knowledge and hardware. It is possible to make a gas generator at home, but if the master does not have a specialized education, there is a high risk of making a mistake. It is easier to rent an argon-arc welding machine, it costs ten times cheaper than making equipment yourself.
welding machine for home use- This is a simplified design with the simplest components and a simple assembly scheme. The main part is a welding transformer, which you can make yourself or use a node household appliance(for example, a microwave oven).
The welding inverter unit is arranged according to the scheme:
You can make a transformer yourself using spent wire cables and a copper tape of the required length.
If round copper wire is used in the transformer, the operation of the machine is limited to 2-3 welding rods. Transformer oil is used for cooling.
The seam on the parts to be joined is formed due to heat, the source of which is an electric arc that occurs between two electrodes. One of the electrodes is the material to be welded. A short circuit, which is required to heat up the electrode (cathode), will lead to a stable discharge with a temperature of up to 6000°C. Under its action, the metal will begin to melt. This is a rough description of the welding process for non-specialists who in everyday life just need to quickly fix the necessary profile, part.
Welding inverters are rarely made on their own. This electronic device requires repeated verification, specific knowledge and experience. It is easier to make a homemade product based on a transformer, and since it must work from a household network (usually 220 V), then to perform small home renovation this device will suffice.
The welding inverter for a 220 V network is assembled according to the scheme that is used for devices operating from an industrial three-phase network. You need to know that these devices will have an efficiency of 60% higher than equipment adapted to a single-phase network.
The welder is made from a transformer without additional components, the package includes:
More complex products inverters are equipped with:
After assembly, the voltage of the secondary winding is measured: the values \u200b\u200bshould not go beyond the parameters of 60-65 V.
Homemade welding transformers are simple equipment for rare repairs. The stator can serve as a magnetic circuit. The primary winding will be connected to the network, the secondary winding is designed to receive an electric arc and perform work. The winding of the transformer consists of copper wire or tape (up to 30 meters).
Primary winding is done with a copper strip with cotton insulation. You can use a "bare" magnetic circuit and insulate it separately. Strips of cotton fabric are wrapped around the wire and impregnated with any varnish for electrical works. The secondary winding is wound after the primary is insulated. The cross section of the primary winding is 5-7 square meters. mm, secondary section - 25-30 sq. mm. After isolation, the parameters are tested: more turns may be required.
The inverter type welding machine has more complex device, can operate on direct or alternating current and provides best quality seam. But if in everyday life only spot welding is required (for example, when repairing household appliances), then the manufacture of an inverter welder is impractical. If a vacuum cleaner or microwave oven transformer is used, it is important not to damage the primary winding. The secondary winding in 80% of cases must be removed and redone so that the unit does not overheat.
The rectifier unit converts the voltage of the AC signal to DC and consists of a small amount small details:
The rectifier is assembled on the principle of a bridge circuit, where an alternating current is supplied at the input, and a constant current is output from the output terminals. Both devices - a transformer and a rectifier for a welder - are equipped with a forced cooling unit. You can use the cooler from the computer power supply.
The inverter unit converts direct current from the rectifier into alternating current and outputs voltage up to 40 V, current strength up to 150 A.
The inverter works as follows:
In the welding device, in addition to the main stages, the current strength is adjusted, optimal ventilation is ensured. You can make an inverter yourself, guided by a detailed diagram.
To assemble the welding machine and manufacture, you will need the following tools and devices:
The parts of the device are assembled on a textolite basis; sheets of aluminum or industrial steel are used for the body.
All parts in the home-made manufacturing scheme of a transformer welder will be arranged in the following order:
The mains filter and rectifier can be excluded from the circuit, but the electric arc will be poorly controlled, and the seam will be of poor quality (uneven, with large torn edges that need cleaning).
Assembly steps:
The weight of the assembled apparatus for minor repairs from 10 kg. It is recommended to make a diode bridge with a choke in a separate case to reduce weight. This node will need to be connected to the welding machine of stainless steel. With alternating mains voltage for iron profile welding, repair body work or point tacks, semi-automatic equipment is practically not required.
A homemade AC welding machine has the following advantages:
The main disadvantage of the contact welding machine is the spattering of metal during operation due to the interruption of the sinusoid of the electric arc and the rapid overheating of the transformer. For welding parts up to 2 mm thick, the electrode diameter should be 1.5-3 mm. Welding of sheets from 4 mm is carried out with rods of 3-4 mm at a machine current of at least 150 amperes.
Homemade DC devices are widely used for the home, but require skill, time and effort to assemble. more small details. Among the advantages of the equipment:
It is recommended that a complete do-it-yourself DC welding machine be checked several times for overheating of the transformer, capacitor and diode bridge in test mode before main operation.
You can make changes to the design of home-made welding machines and constantly refine them. You can make a unit that runs on direct current, a minimal design that runs on an alternating signal with a minimum power of up to 40A, or a massive stationary unit for installation in a workshop.
A welding machine cannot be called an essential tool at home, such as a screwdriver or a hammer. However, there are situations when a welding machine is really necessary. IN this material we will consider how to assemble a simple welding machine at home.
First of all, we suggest watching a video on the manufacture of a welding machine
So, we need:
- water tank;
- salt;
- water;
- two metal plates;
- wire with a plug;
- two wires;
- welding electrode.
According to the homemade author, the creation process takes only 15 minutes, so let's not waste time in vain and move on to making a homemade welding machine. First of all, we need to take one metal plate and fasten one of the two wires to it.
We repeat the process with the second plate and the second wire.
Next, add two tablespoons of salt to the water and mix everything well.
In the resulting mixture, we immerse two plates and wires wound on them.
For safety reasons, metal plates are advised to be fixed with clothespins.
The plates actually allow you to adjust the welding current. How exactly does it work? The deeper we immerse the plates, the more current we get.
We must connect one wire coming from one of the plates to the phase, and the second wire to the welding electrode.
We also take the neutral wire and connect it to the object that we need to cook.
A completely logical question arises - how can you determine where the phase is and where is zero, if for some reason there are no special measuring devices at home. There is an old the right way: You just need to touch the wire to the ground. The wire that will spark when it touches the ground is the phase wire.
With this simple welding machine, you can cut thin metals, weld copper wires, and engrave metal surfaces. Other applications can be easily found. Such a mini welding machine can be powered by 12-24 V.
The welding machine is based on a high-voltage high-frequency converter. Built on the principle of a blocking oscillator with deep transformer feedback. The generator generates short-term electrical impulses that repeat at relatively large intervals. The clock frequency is in the range of 10-100 kHz.
The transformation ratio of this circuit will be 1 to 25. This means that if you apply a voltage of 20 V to the circuit, then the output should be about 500 V. This is not entirely true. Since any impulse transformer source or generator without load has powerful high-voltage impulses, reaching a voltage of 30,000 V! Therefore, if you disassemble any impulse Chinese charging, you will see a soldered resistor parallel to the output capacitor. This is also a load network, without a resistor, the output capacitor will quickly leak due to overvoltage, or worse, it will explode.
Therefore, attention! The voltage at the output of the transformer is life threatening!
The welding machine is a fairly popular device among both professionals and home craftsmen. But for domestic use sometimes it makes no sense to buy an expensive unit, since it will be used in rare cases, for example, if you need to weld a pipe or put up a fence. Therefore, it would be wiser to make a welding machine with your own hands, investing a minimum amount of money in it.
The main part of any welder operating on the principle of electric arc welding is a transformer. This part you can remove from old, unnecessary household appliances and make a homemade welding machine out of it. But in most cases, the transformer needs a little refinement. There are several ways to make a welder, which can be both the simplest and more complex, requiring knowledge in radio electronics.
To make a mini welding machine, you will need a couple of transformers taken from an unnecessary microwave oven. A microwave is easy to find with friends, acquaintances, neighbors, etc. The main thing is that it has a power in the range of 650-800 W, and the transformer in it is working. If the stove has a more powerful transformer, then the device will turn out with higher current rates.
So, a transformer removed from a microwave oven has 2 windings: primary (primary) and secondary (secondary).
Resale has more turns and a smaller wire cross section. Therefore, in order for the transformer to become suitable for welding, it must be removed and replaced with a conductor with larger area sections. To remove this winding from the transformer, it must be cut on both sides of the part with a hacksaw.
This must be done with special care so as not to accidentally touch the primary winding with a saw.
When the coil is cut, its remains will need to be removed from the magnetic circuit. This task will be much easier if you drill the windings to relieve the stress of the metal.
Do the same with the other transformer. As a result, you will get 2 parts with a primary winding of 220 V.
Important! Don't forget to remove the current shunts (shown with arrows in the photo below). This will increase the power of the device by 30 percent.
For the manufacture of the secondary, you will need to purchase 11-12 meters of wire. It must be multi-core and have cross section of at least 6 squares.
To make a welding machine, for each transformer you will need to wind 18 turns (6 rows in height and 3 layers in thickness).
Both transformers can be wound with one wire or separately. In the second case, the coils should connect in series.
The winding should be made very tight so that the wires do not hang out. Next, the primary windings need connect in parallel.
To connect the parts together, they can be screwed to a small piece of wood board.
If you measure the voltage on the secondary of the transformer, then in this case it will be equal to 31-32 V.
With such a home-made welder, metal 2 mm thick is easily welded with electrodes with a diameter of 2.5 mm.
It should be remembered that cooking homemade apparatus follows with breaks for rest, since its windings are very hot. On average, after each used electrode, the device should cool down for 20-30 minutes.
Thin metal with a unit made from a microwave will not be able to cook, as it will cut it. To adjust the current, a ballast resistor or choke can be connected to the welder. The role of a resistor can be performed by a piece of steel wire of a certain length (selected experimentally), which is connected to a low-voltage winding.
This is the most common type of apparatus for welding metals. It is easy to make at home, and it is unpretentious in operation. But main disadvantage apparatus is large mass of step-down transformer, which is the basis of the aggregate.
For home use, it is enough that the device produces a voltage of 60 V and can provide a current of 120-160 A. Therefore, for primary, to which a 220 V household network is connected, a wire with a cross section of 3 mm 2 to 4 mm 2 is required. But perfect option- this is a conductor with a cross section of 7 mm 2. With such a cross section, voltage drops and possible additional loads will not be terrible for the device. From this it follows that for the secondary you need a conductor having a diameter of 3 mm. If you take aluminum conductor, then the calculated cross section of copper is multiplied by a factor of 1.6. For resale a copper bus with a cross section of at least 25 mm 2 is required
It is very important that the winding conductor is covered with rag insulation, since the traditional PVC sheath will melt when heated, which can cause an interturn short circuit.
If you did not find a wire with the required cross section, then it can be make your own from several thinner conductors. But at the same time, the thickness of the wire and, accordingly, the dimensions of the unit will increase significantly.
First thing, the basis of the transformer is made - the core. It is made of metal plates (transformer steel). These plates should have a thickness of 0.35-0.55 mm. The studs connecting the plates must be well insulated from them. Before assembling the core, its dimensions are calculated, that is, the dimensions of the “window” and the cross-sectional area of the core, the so-called “core”. To calculate the area, use the formula: S cm 2 \u003d a x b (see figure below).
But it is known from practice that if a core with an area of less than 30 cm 2 is made, then it will be difficult to obtain a high-quality seam with such an apparatus due to a lack of power reserve. Yes, and it will heat up very quickly. Therefore, the cross section of the core must be at least 50 cm 2 . Despite the fact that the mass of the unit will increase, it will become more reliable.
To assemble the core, it is better to use L-shaped plates and place them as shown in the following figure until the thickness of the part reaches the required value.
At the end of the assembly, the plates must be fastened (at the corners) with bolts, then cleaned with a file and insulated with fabric insulation.
Now we can start transformer winding.
One caveat should be taken into account: the ratio of turns on the core should be 40% to 60%. This means that on the side where the primary is located, there should be fewer turns of the secondary. Due to this, at the start of welding, the winding with more turns will be partially switched off due to the occurrence of eddy currents. This will increase the current strength, which will positively affect the quality of the seam.
When the winding of the transformer is completed, network cable connects to a common wire and to a branch of the 215th turn. Welding cables are connected to the secondary winding. After that, the contact welding machine is ready for operation.
To cook cast iron or stainless steel, a DC apparatus is required. It can be made from a conventional transformer unit, if its secondary winding connect rectifier. Below is a diagram of a welding machine with a diode bridge.
Scheme of a welding machine with a diode bridge
The rectifier is assembled on D161 diodes, capable of withstanding 200A. They must be installed on radiators. Also, to equalize the current ripple, you will need 2 capacitors (C1 and C2) for 50 V and 1500 uF. This circuit also has a current regulator, the role of which is performed by the inductor L1. Welding cables are connected to contacts X5 and X4 (direct or reverse polarity), depending on the thickness of the metal to be joined.
It is impossible to make a welding machine from a computer power supply. But using its case and some parts, as well as the fan, is quite realistic. So, if you make an inverter with your own hands, then it can easily be placed in the PSU case from the computer. All transistors (IRG4PC50U) and diodes (KD2997A) must be installed on radiators without the use of gaskets. For cooling parts, it is desirable use a powerful fan, such as Thermaltake A2016. Despite its small size (80 x 80 mm), the cooler is capable of 4800 rpm. The fan also has a built-in speed controller. The latter are regulated using a thermocouple, which must be mounted on a radiator with installed diodes.
Advice! It is recommended to drill several additional holes in the PSU case for better ventilation and heat dissipation. The overheating protection installed on the radiators of the transistors is set to operate at a temperature of 70-72 degrees.
Below is the basic circuit diagram welding inverter(in high resolution), which can be used to make a device that fits in the PSU case.
On following photos it shows what components a homemade inverter welding machine consists of, and how it looks after assembly.
To make a simple welding machine from the stator of an electric motor, it is necessary to select the motor itself that meets certain requirements, namely, that its power is from 7 to 15 kW.
Advice! It is best to use a 2A series motor as it will have big window magnetic circuit.
You can get the right stator in places where scrap metal is accepted. As a rule, it will be cleaned of wires and after a couple of blows with a sledgehammer it will split. But if the body is made of aluminum, then in order to remove the magnetic circuit from it, stator needs to be annealed.
Place the stator with the hole up and place bricks under the part. Next, stack the wood inside and set it on fire. After a couple of hours of roasting, the magnetic core will easily separate from the body. If there are wires in the housing, they can also be removed from the grooves after heat treatment. As a result, you will receive a magnetic circuit cleaned of unnecessary elements.
This blank should be well saturate with oil varnish and let it dry. To speed up the process, you can use heat gun. Impregnation with varnish is done so that after removing the screeds, the package does not spill.
When the blank is completely dry, using the grinder, remove the ties located on it. If the ties are not removed, they will act as short-circuited turns and take power from the transformer, as well as cause it to heat up.
After cleaning the magnetic circuit from unnecessary parts, you will need to make two end caps(see picture below).
The material for their manufacture can be either cardboard or pressboard. You also need to make two sleeves from these materials. One will be internal, and the second - external. Next, you need:
After carrying out the above steps, it will be possible to make a welding transformer from the magnetic circuit. For these purposes, you will need a wire covered with fabric or glass-enamel insulation. To wind the primary winding, you need a wire with a diameter of 2-2.5 mm. The secondary winding will require about 60 meters of copper bus (8 x 4 mm).
So, the calculations are done as follows.
For primary winding a conductor with a diameter of 2.36 mm is suitable, which needs to be folded in half. In principle, you can take any wire with a diameter of 1.5-2.5 mm. But first you need to calculate the cross section of the conductors in the coil. First you need to wind the primary winding (at 220 V), and then the secondary. Its wire must be insulated along its entire length.
If you make a tap in the secondary winding in the area where 13 V is obtained and put a diode bridge, then this transformer can be used instead of the battery if you want to start the car. For welding, the voltage on the secondary winding should be in the range of 60-70 V, which will allow the use of electrodes with a diameter of 3 to 5 mm.
If you have laid both windings, and in this design there is free place, then you can add 4 turns of a copper bus bar (40 x 5 mm). In this case, you will receive a winding for spot welding, which will allow you to connect sheet metal up to 1.5 mm thick.
For case manufacturing metal is not recommended. It is better to make it from textolite or plastic. In places where the coil is attached to the body, rubber gaskets should be laid to reduce vibration and better insulation from conductive materials.
The finished spot welding machine has a rather high price, which does not justify its internal “stuffing”. It is arranged very simply, and it will not be difficult to make it yourself.
To make a spot welding machine yourself, you need one transformer from a microwave oven with a power of 700-800 watts. It is necessary to remove the secondary winding from it in the manner described above, in the section where the manufacture of a microwave welding machine was considered.
The spot welding machine is made in the following way.
In this case, the result was positive. Therefore, the creation of a spot welding machine can be considered completed.
From the article you will learn what it is to make them with your own hands is quite simple, if you have elementary knowledge in electrical engineering and necessary tools. As a basis for a welding machine, both a ready-made transformer and a home-made one can be taken.
Of course, such designs consume a lot of power, therefore, a strong voltage drop will be observed in the network. This may affect the operation of household electrical appliances. It is for this reason that designs based on semiconductor elements are much more effective. To put it simply, these are devices.
So, the first thing to consider is the most simple designs that anyone can repeat. Of course, these are the devices based on transformers. The design discussed below allows you to work on voltages of 220 and 380 volts. The maximum electrode diameter used in welding is 4 mm. Thickness of welded metal elements ranges from 1 to 20 mm. About that, you now know in full. And you can move from simple to complex.
Despite such excellent characteristics, the manufacture of the welding machine is made from readily available materials. You will need a three-phase step-down transformer for assembly. At the same time, its power should be about 2 kilowatts. It is also worth noting that you will not need all the windings. Therefore, in the event that one of them fails, there will be no problems with further design.
The bottom line is that you only need to make changes in the secondary winding. To facilitate the task, the article below shows a diagram of the welding machine, its connection to the network is also described.
So, the primary winding does not need to be touched, it has all the characteristics necessary for operation from the network alternating current 220 volt. There is no need to disassemble the core, it is enough to disassemble the secondary winding directly on it, and wind a new one instead.
The transformer you have to choose has several windings. Three primary, the same number of secondary. But there are also medium windings. There are also three of them. It is instead of the middle one that it is necessary to wind the same wire that was used to make the primary one. Moreover, it is necessary to make taps from every thirtieth turn. About 300 turns in total should have each winding. Due to the correct winding of the wire, the power of the welding machine can be increased.
The secondary winding is wound on both extreme coils. It is difficult to specify the exact number of turns, since the more, the better. The wire is used with a cross section of 6-8 square millimeters. Together with it is wound at the same time thin wire. As a power cable, you need to use a stranded cable in reliable insulation. That's how they do it by hand.
If we analyze all the structures made using this technology, it turns out that the approximate amount of wire is about 25 meters. If there is no wire with a large cross section, you can use a cable with an area of 3-4 square millimeter. But in this case, it must be folded in half when winding.
The design has a simple welding machine. A semi-automatic device can be made on its basis if one more winding is made to power the electric drive for supplying electrodes. Please note that the output of the transformer will be a very large current. Therefore, all switching connectors must be made as durable as possible.
To make terminals for connecting to the secondary winding terminals, you will need copper tube. It should have a diameter of 10 millimeters and a length of 3-4 cm. It needs to be riveted from one end. You should get a plate in which you need to make a hole. Its diameter should be about one centimeter. Wires are inserted from the other end. Regardless of whether the welding machine is DC or AC, switching is made as rigid and reliable as possible.
It is desirable to clean them perfectly, if necessary, treat them in acid and neutralize it. To improve contact, the second edge of the tube should be slightly flattened with a hammer. The conclusions of the primary winding are best attached to the textolite board. Its thickness should be about three millimeters, it can be more. It is rigidly attached to the transformer. In addition, 10 holes need to be made in this board, each with a diameter of about 6 millimeters. Look at the scheme of the welding machine, how it is connected to the 220 and 380 Volt network.
They need to install screws, nuts and washers. The conclusions of all primary windings are connected to them. In the event that welding is required to work from a 220-volt household network, the extreme windings of the transformer are connected in parallel. The middle winding is connected in series with them. Welding will work ideally when powered by 380 volts.
To connect the primary windings to the mains, you need to use a different scheme. Both extreme windings are connected in series. Only after that, the middle winding is switched on in series with them. The reason for this lies in the following: the middle winding is additional, with its help, the voltage and current are reduced during secondary circuit. Thanks to this, welding machines made by their own hands according to the above technology work in normal mode.
Certainly, an integral part of any welding machine is an electrode holder. There is no need to buy ready-made, if you can make it from improvised materials. You need a three-quarter pipe, its total length should be about 25 centimeters. At both ends, it is necessary to make small notches, about 1/2 of the diameter. With such a holder, the welding machine will work normally. For plastic elements design is a separate requirement - they must be located as far as possible from the transformer and holder.
They need to be done three to four centimeters from the edge. Then take a piece of steel wire with a diameter of 6 millimeters, weld it to the pipe opposite the larger recess. On the other hand, it is necessary to drill a hole, attach a wire to it, which will be connected to the secondary winding.
It is worth noting that you need to connect the welding machine in accordance with all the rules. First, you need to use a knife switch, with which you can easily disconnect the device from the network. Please note that do-it-yourself welding machines, in terms of safety, should not be inferior to analogues manufactured by the industry. Secondly, the cross section of the wires for connecting to the network must be at least one and a half square millimeters. The current consumption of the primary winding is a maximum of 25 amperes. In this case, the current can be changed in the range of 60..120 amperes. Please note that this design is relatively simple, so it is only suitable for domestic use.
A spot type welding machine will also be useful. The designs of such devices are no less simple than the previous ones. However, the output current is very large. But it is possible to produce resistance welding of metals up to three millimeters thick. In most designs there is no adjustment of the output current. But you can do it if you wish. True, the whole homemade work becomes more complicated. The need to regulate the output current is eliminated, since the welding process can be controlled visually. Of course, inverter welding machines will be much more efficient. But point ones can do things that no other design can do.
For manufacturing, you will need a transformer with a power of about 1 kilowatt. The primary winding remains unchanged. Only the secondary will need to be redone. And if a transformer from a household microwave oven is used, then you need to knock out the secondary winding, instead winding several turns of large-section wire. If possible, it is better to use a copper bus. The output should be about five volts, but this will be enough for the full operation of the device.
Here it is slightly different from the one discussed above. For the manufacture you will need small duralumin blanks. Suitable rods with a diameter of 3 centimeters. The lower one must be motionless, completely isolated from the contacts. As insulating material you can use washers made of textolite, as well as varnished cloth. Any, even the simplest spot welding machine needs a reliable electrode holder, so pay maximum attention to its design.
The electrodes are made of copper, their diameter is 10-12 millimeters. They are firmly fixed in the holder with rectangular brass inserts. The initial position of the electrode holder - its halves are divorced. Springs can be used to give elasticity. Perfect for old cots.
It is necessary to connect such welding to the electrical network using circuit breaker. He must have rated current 20 amps. Pay attention to the fact that at the input (where you have the counter) the machine must be either the same in terms of parameters or larger. To turn on the transformer, a simple magnetic starter is used. The operation of a contact-type welding machine is somewhat different from the one discussed above. And now you will find out these features.
To turn on the magnetic starter, it is necessary to provide a special pedal that you will press with your foot to generate current in the secondary circuit. Please note that resistance welding is switched on and off only if the electrodes are fully brought together. If you neglect this rule, then a lot of sparks will appear, as a result, this will lead to burning of the electrodes, their failure. Try to pay attention to the temperature of the welding machine as often as possible. Take small breaks from time to time. Do not allow the unit to overheat.
It is the most modern, but more difficult to design. It also uses semiconductor transistors with high power. Perhaps these are the most expensive and scarce parts. First of all, the power supply is made. It is pulsed, so it is necessary to make a special transformer. And now in more detail about what such a welding machine consists of. See the specifications of its components below.
Of course, the transformer used in the inverter is much smaller than those discussed above. You will also need to make a throttle. So, you should get a ferrite core, a frame for making a transformer, copper tires, special brackets to fix the two halves of the ferrite core, electrical tape. The latter must be chosen based on the data of its thermal stability. Stick to these tips when making inverter welders.
The transformer is wound over the entire width of the frame. Only under this condition will it be able to withstand any voltage drop. For winding, either a copper bus or wires assembled in a bundle is used. Please note that aluminum wire cannot be used! It can't handle that much density. electric current which is present in the inverter. Such a welding machine for giving is able to help you out, and its weight is extremely small. The coils are wound as tightly as possible. The secondary winding is two wires with a thickness of about two millimeters, twisted together.
They should be isolated from each other as much as possible. If you have large stocks from old TVs, you can use them in the design. It takes 5 pieces, and you need to make one common magnetic circuit out of them. In order for the device to work with maximum efficiency, you need to pay attention to every little thing. In particular, the thickness of the wire of the output winding of the transformer affects its continuity.
To make a welding machine 200, you need to pay maximum attention to all the little things. In particular, power transistors must be mounted on a heatsink. Moreover, the use of thermal paste is welcomed to transfer heat from the transistor to the radiator. And it is recommended to change it from time to time, as it tends to dry out. In this case, heat transfer worsens, there is a possibility that semiconductors will fail. In addition, you need to do forced cooling. For this purpose, exhaust coolers are used. Diodes used to rectify alternating current must be fixed to aluminum plate. Its thickness should be 6 millimeters.
The connection of the terminals is carried out using an uninsulated wire. Its cross section should be 4 mm. Pay attention to the fact that between the wires of the connection there is maximum distance. They should not touch each other, no matter what impact the body of the welding machine experiences. The throttle must be fixed to the base of the welding machine with a metal plate.
Moreover, the latter should completely repeat the shape of the throttle itself. To reduce vibration, it is necessary to install a rubber seal between the housing and the throttle. Power wires inside the device are bred into different sides. Otherwise, there is a possibility that a short circuit will occur. It is necessary to install the fan in such a way that it blows all the radiators at the same time. Otherwise, if you cannot use one fan, you will have to install several.
But it is better to fully calculate in advance the installation location of all elements of the system. Please note that the secondary winding must be cooled as efficiently as possible. As you can see, not only radiators need effective airflow. On this basis, it is possible to make an argon welding machine at no cost. But its design will require the use of other materials.
Now you know how to make several types of welding machines. If you have skills in the design of electronic equipment, then it is better, of course, to stop at an inverter welding machine. You will spend time, but at the end you will get an excellent device that is not inferior even to expensive Japanese counterparts. Moreover, its production will cost mere pennies.
But if there is a need to make a welding machine, as they say, in haste, then it will be easier to connect two transformers from microwave ovens with modified secondary windings. Subsequently, the entire unit can be improved by adding to it electric drive for supplying electrodes. You can also install a balloon filled with carbon dioxide in order to carry out welding of metals in its environment.
