As I do not have facility to compile the C code, could you please upload a copy of the 'HEX' code? The things that kill capacitors, especially electrolytic, are excessive voltage, and heat. (Critically, with battery spot welding the weld current must pass through two points on the same side of the battery terminal - not through the battery! All in all, lot's of drilling, but I was able to pull blown fets in a minute, and isolate them within 3 minutes. Kyriakos on 16th Jan 2014 Dear Mr. Ian Hooper, Thanks verry much for your yesterdays' quick response. Ian Hooper on 12th Jul 2013 Hmm I'm not sure regarding the flyback diode. If the capacitors were to discharge as soon as they touched the nickel strip, it might just melt a hole in the strip without welding it to the battery. Video showing spot welding will follow soon. You are unforgettable. P-channel devices usually have higher on-resistance. Electrodes Touch. The same function could also be done with something like a 555 timer, but I like the precision of a microcontroller, and it actually involves a lower total part count. It was a bit of an inexact science! Figure 3. They are absolutely great transistors with small Rdson (5.5mOhm at 10V), high current rating(305A pulsed drain current), relatively small gate charge(38nC typical), fast rise and fall time (15nS and 5nS). The ultras are intimidatingly powerful. Ian Hooper on 21st Jul 2013 Yes, it is plausible that the Equivalent Series Resistance of the cheap 2.5F cap is too high for it to output the required current. Ian Hooper on 1st Jun 2013 The micro code translated that adjustment pot into a pulse duration range between 25-275ms or so. For welding 2mm copper wire onto the brass plate of 1mm you dont need 3000 DCA, you would be ok with aluminium welder 100 A. Welding my application 5 mm Aluminium i use 180-200 A. Andrew on 20th Jun 2012 Can you please post a schematic of your control board assembly? I imagine it's overkill, but sometimes it's nice to have a bit of safety margin. Then from the other side, starting from the charger to the positive (+), terminal of the cacitor bank to the + positive Red prod. Sep 7, 2018 - Schematic of a simple capacitor spot welder. I thought 4 capacitors may work fine if delivered energy as follows is calculated: 2.7V*4=10.8V; 1500F/4=375F and in the end E = 1/2 CV² = 0.5*375F*10.8^2= 21 870J. Probably the simplest option. Having all them in parallel you could have 20x2000 => 40,000A, but of course the overall resistance will limit the current an the capacitors are not able to support all this current. I'm reckoning that the low voltage and high capacity should be fine for doing a slow wield using only thyristor and manually removing the electrode from work piece to break the circuit. Separate power supplies for capacitors and logic circuit must be used because the ultracaps charge very slowly (about a minute to reach welding voltage), and the AVRs don't particularly like such a slow ramp up of supply voltage. (As discussed with Sylvia in an earlier comment, because the capacitors vary by ~10% or so, you need to only charge to 10% lower than the theoretical maximum to ensure none get damaged.). First clean the second weld. It also simplifies a CD welder because you don't need two capacitor banks for two-pulse welding. Can i drive the mosfet directly from micro controller instead of gate driver? (Actually if I did the project again I'd probably look at using 20V SMD MOSFETs, since running many in parallel should offer low enough on-resistance as to not even need heatsinking. And higher current is harder to control/switch, of course. :) Thanks in advance -Greg. I tried 4*27000uf+1*100000uf which is 208k in total & the results is better than the super cap. Resistance Weld Equipment Process Guide. Ian Hooper on 21st Jun 2013 IRL7833 looks like a decent choice, their voltage rating should be fine unless you're getting some significant inductive v spikes. Generally you won't need any of them to approach max voltage. Will post result once I done everything. The capacitors discharge energy is dissipated due to the metal resistance in the form of heat which melts and fuses metal pieces. Also, if you are interested in a more heavy duty work than capacitor-based device can handle, a transformer-based spot welder is the best choice. However, when dealing with several hundred or possibly over a thousand amps such as in the case of a welder, microOhms count. I expect you'd need a lot more power to weld 0.5mm material! This spot welder contains a very large capacitor that is charged to a precise voltage then discharges through the material to produce a controlled cut. The power board layout is pretty much as per my most recent controller designs. Easiest option may be to build or buy a 1 Farad capacitor as per their designs! Have you noticed the sparks? Comporents , wiring and adjustments used: 6 Maxwel Ultra Capacitors 350 farad 2.7 volts in psrallel. meguit@rist on 12th Jul 2013 Thanks for yr opinion Ian. Two common examples are the 18650 and 26650 sizes of lithium cell. That will give you around 1,6uF at 16V. My completed CD spot welder is pictured to the left. Weld times vary from 0.01 to around 1 second. arran on 26th Aug 2013 I think the capacitor will charge quick enough that the virtual short will only be a couple of seconds, I would try not to discharge it completely so for multiple wields the cap will have a good initial resistance for subsequent charges (in theory...) I'll be using 200A thyristor and quarter inch copper as the electrodes, my main concern is that the 4x 2.7v caps will have their legs blown off/melted on discharging. I also ended up drilling my buss bars for ic legs, then drilling and tapping perpendicular to it so I can "clamp" the fet and diode legs in place as you would on a terminal block. ), Commercial CD welders typically cost several thousand dollars. I suspect small ones on jewellery, maybe up to things like cooking pots etc. Some construction pictures: Pulse controller on bread Board with a 555 and a MIC4452 driver. Thanks in advance. Will these capacitors sufficient for welding battery tab? 45 Minutes initial Charging time. As can be seen from the pictures at the top, the welds are quite small but hold on tenaciously and should be good for about 10A per spot. SCRs can't be turned off (they turn themselves off once there's zero voltage across the power terminals), but with a 1F capacitor you just discharge it completely through the weld so there's no issue using SCRs if it works out more economical. You concentrate a lot of energy into a small spot, where the voltage drop increases and the heat is generated. In the first current pulse the metal is softened to reduce contact resistance on the red spots, than it is let to cool down. I am ready to repeat doing the entire welder from the very beginning. Ian Hooper on 20th Feb 2015 Hi kyriakos, it sounds like you have a good set of components so the main possible problem that comes to mind is the total circuit resistance may be restricting current flow - in particular, connections between the capacitors since there's basically a dozen joints there. There is enough time to turn on and off the FETs at least two times in half a second, the time required for welding. Running six in series results in 108 Farads at up to ~16V. They have around 0.030 Ohm of internal resistance and at 2.7V the maximum current they can output will be I=2.7V/0.030Ohms around 90 Amps that is low for a Spot welder. Ian Hooper on 28th Dec 2012 Hi Azzy, hmm I'm surprised to hear you observed reverse voltages happening on the capacitor. And if they did contribute to the failure of at least one MOSFET, would you know if you only had five of the working? This project is work in progress. Alan on 17th Jul 2012 I have 6 pieces of 47000uF 80V computer grade capacitors. Grab a copy here. Supercap. Resistance Welding Spot Seam Projection Welding. A common method for doing this is with Capacitive Discharge (CD) spot welding, which basically involves dumping a pulse of energy stored in a capacitor through the nickel strip, causing localised melting of the nickel and welding it to the battery. This DC Power source charges the capacitor, if the switch is pressed it activates the Relay 1 and charge of capacitor activates the Relay 2, Since capacitor can hold very few amounts of energy it quickly discharges and Relay 2 turns off ... Schematic_Spot-welder_Sheet-1_20190302212716.pdf. Not bad for under $70, ho! We'll see if anyone else has any ideas/comments too.. kyriakos on 20th Feb 2015 Dear Ian Thanks once again for your almost immediate response. I'm not familiar with how the equivalent is done on Arduinos, but hopefully Google can tell you how to enable pull up pins on the Arduino! Have you found a better source of nickel strip yet? With a quantity of K2 26650EV cells sitting in my workshop, orphans from a cancelled project, it seemed like a good idea to build myself a CD welder such that I could assembly these cells into packs suitable for use in my various electric vehicle projects. Kyriakos. Ian Hooper on 24th Feb 2014 Hi Kyriakos, it sounds like you may have the MOSFETs wired up incorrectly. Schematics: Firstly, I've had a few requests for the schematics, so here they are (click for enlargements, or here for the Eagle file). Be sure to wear safety glasses! fig. I actually can't get IXDD414s anymore in my country (Australia) either! Mark on 3rd Jan 2013 thank you for fast response. John on 24th Mar 2013 Hi! Hackaday’s own [Sean Boyce] even made one … Because 1 nano second is the 1/100.000.000 of a second or in other words one nano second is  one billionth of a second. With this figure you can work out how much voltage and capacitance you will need for each weld, based on the formula for energy stored in a capacitor: Hence at 15V, I would need about 1.8 Farad per weld. I'd be interested to hear from anyone who knows of a good source of nickel strip in Australia. Thanks can you send it to my email address xxxxxx@libero.it. My two concerns are would the resistance of working materials be enough to prevent the caps from instantly discharging and also would 9v actually be enough to wield with? Is there a diode across the caps to prevent that? Capacitive Discharge Spot Welders use energy stored in capacitors to discharge a large pulse of current through electrodes to create a spot weld. The pulse timer is based on an Atmel ATtiny13A microcontroller. I keep testing particularly the output of my project till I find why this lack of 100 amps. Spot welders based on capacitors use large capacitors to store electrical energy and release it quickly. I think using super capacitors is my best option for building a higher power spot welder. It seemed like a good idea, but without realising the consequence at the time, I had greatly reduced the overall resistance of the weld circuit, which greatly increased weld current, and blew the new MOSFETs! I'm not sure how a shorted mosfet would jeopardize others, but on account of being a little timid about switching a kJ capacity reserve, spending twice as much on mosfets doesn't sound entirely like an unwise investment if there's some potential a heavily worked mosfet might lock into an on state. [inaritcle_1] Useful Steps . That said the physical layout got tested thoroughly when I was developing it as a motor controller and I can confirm that the devices share the load well, even at much faster switching than the spot welder. Spot Welder Dr Justins Hobbies. Try Aliexpress.com (China)for mosfets. Analysis of Capacitor Discharge Welding Electrical Response A schematic representation of the electrical circuit for capacitor discharge welding is provided in Figure 2. Thanks once again. Using a few low voltage MOSFETs in parallel is much cheaper and more efficient. capacitor spot welder schematic for sale - 0 - capacitor spot welder schematic wholesalers & capacitor spot welder schematic manufacturers from China manufacturers. (The ones I'm using are 2.7V each so 16.2V theoretical max, but I only needed to charge them to 10-12V for welding; plenty of headroom for variations in voltage.). Energy is of course power (or volts x amps) x time, so bumping up the time can compensate for lower power delivery. My welders were basically built around recycled motor controller power stages - just what I had lying around, not necessarily the best tool for the job! Could it be the cheap 2.5F super cap not as super as 2.5F? ... June 2012 Update: Schematics, Repairs, Upgrades and Musings. They're actually part of an old motor controll assembly I had lying around. I will do the same then! 32-28awg. N-channel FETs are usually used as "pull-downs", so you'd need the capacitor bank +ve going to one electrode, the other electrode going to the Drain on the FETs, and the Source connected to capacitor -ve. wire back to a common point. BE EXTREMELY CAREFUL when working with 220V AC sources & high voltage capacitors.. 1) Remove the leads of the two electrical probes & solder them on the ends of the 1.5mm insulated copper wire. -Greg. Joel on 14th Jan 2014 Hello a very nice project , I starting a discharge spot welder from an old electronic book, can I submit you the electronic drawing? meguit@rist on 12th Jul 2013 I'm thinking of disconnect the power source during spot. The 4kw transformer welder has approximately 8V open circuit voltage. I also installed a 100ohm bypass resistor to slowly discharge the capacitors. But possibly better for CD welders would be ones like IRFP4468 or IRFP4368 for the higher current rating and lower on-resistance. current during the crucial discharge (pulse). And what about a charged up capacitor? As such I'm not really familiar with how much weld current or energy is required for that! Clearly 108F is much more than necessary, and unlike the other designs above I need to be able to start and stop my pulse (not discharge the entire capacitor energy in a single weld), but having such a large capacitance does allow for many welds in quick succession, if desired. The easy solution is probably to monitor all the individual capacitor voltages while they're charging up and make sure none are exceeding their voltage limit. Nickel strip can be purchased from Powerstream or Sunstone Engineering. I found the specs for Maxwell BCAP3000 P270, and it seems that maximum peak current (1 second) is 2200A and 0.29 mΩ resistance. Also, the MOSFETs were all triggered by the same gate driver. With long leads and thus hugher inductance for sure. Look HERE to see what documents are included in this downloadable package. The circuit was tested. The datasheets for most MOSFETs list a maximum switching time and a typical switching time, usually on the order of Microseconds. It's pretty straight forward. I'm looking for suitable studs and a stud-holder/gun. The following are the steps on ‘How To make a spot welder’. Have you looked into these for either welding or for your vehicle motor controllers? Ian Hooper on 12th Feb 2014 It's an interesting idea. Interesting that you got better results with just 0.2F capacitance! The P-channel MOSFET (eg. Ian Hooper on 19th Aug 2012 Hi Sylvia, you are correct! The amount of stored energy can be controlled by rotating the … It might be interesting to experiment longer pulses at lower current, or vice versa (though shorter pulse at higher current would need beefier switching devices). However, the energy stored in the capacitor is a function of the voltage squared (E = ½*C*V2). Based on research, I learned that a typical battery spot weld requires approximately 200 Joules of energy. The principles of CD welding are simple. The weld algorithm continuously monitors output voltage and current, and by this it takes input voltage/current changes into account when calculating the accumulated weld energy. The desired voltage and welding pulse duration will be displayed and can be modified on a 16×2 LCD screen. Works well. When one of the IXFX120N20s blew, I replaced the lot with IRFP2907s, a lower voltage FET with much lower on-resistance (about 5mohm instead of 20mohm). They use an SCR switch and you use MOSFETs. Thanks in advance for your help! If I fail building it, than the whole project is failed. 3V would only get 300A which may not be enough for a good weld. howard in NZ on 20th Jul 2013 Hi, I have been looking at similar circuits for discharge magnetising. He published schematics and PCB design, has rewritten my original firmware to C++ and implemented the cutting operation mode. But, keep in mind when I say high and low resistance, the values varies around 0.1-0.001 ohms. Would love to see more shots showing how everything is mounted! easy test capacitors diodes rectifiers ... hvac training schematic symbols youtube. Why? azzythehillbilly on 28th Dec 2012 Very nice blog. As for SCRs, the problem is that you can't turn them off once they start conducting, the current has to stop flowing by itself, so would have no choice but to discharge the ultracap entirely - which is a lot of energy! For power switches I am using 20 pcs of 80V 100A CSD19501KCS MOSFETs from Texas Instruments. Ian Hooper on 23rd Jun 2012 Done! The IRL7833s I have are the TO220s, worth seeing if they have them in TO247s then...they were dirt cheap, but I noticed one passed current without a gate signal...after removal of that one, others had the same issue after one or two welds...like the gate was stuck closed. Here we got the setup: I got a best of 180 ns rise time, and a slightly shorter fall time (at around 150 ns). meguit@rist on 10th Jul 2013 hello Ian, Thanks for yr prompt reply. The power supply doesn't do much during the actual weld time. ), A common method for doing this is with Capacitive Discharge (CD) spot welding, which basically involves dumping a pulse of energy stored in a capacitor through the nickel strip, causing localised melting of the nickel and welding it to the battery. One author in the Endless Sphere e-bikes tab welding thread (Texaspyro) mentioned that he prefers always having two mosfets in series, such that if one of the pair shorts on (apparently a danger?) 10 ms single pulse adjusted with oscilloscope. You are really unforgettable. In the next part I am going to test both the FETs and the capacitors, and trying to figure out the maximum power that can be delivered through the welding electrodes. Fixing/upgrading it was quite a learning experienced, speckled with several other blown MOSFETs. Battery tab welding typically requires 15Vdc to achieve an optimal current across the welding area. Ian Hooper on 24th Mar 2013 Hi John, they would have plenty of energy and low enough resistance for the job, but you may need more than four for sufficient voltage.. Thanks! Just ballpark figures but you get the idea. 3 – power electronics schematic. The first possible problem that comes to mind is that you kind of need the probes to be applying pressure to the contact before the discharge starts. Or the mains power outlet? Thanks in advance. Good price too at about $6ea. this will get 1.66farad & up to 15v supply rite? Do you think I have any chance to succeed? Schematics, Microcontroller software, PCB layout to be added. 3): fig. I have read that the spot weld itself needs about 200 joules - not sure if that's per spot or for a pair, but at any rate it's clear that the equipment is soaking up most of the energy rather than delivering it to the weld. I am using 35mm2 copper wire, approximately 1 meter total wire length (back and forth) from the transformer to the spot welding electrodes. meguit@rist on 30th Jul 2013 Hello Ian, I just bought 27x27k.uf 35v cap today & tested 8 cap in parallel. The red spots represents the low resistance contact where the smallest possible voltage drop needs to be achieved, between the welding electrodes and the nickel strap. My completed Ultra Capacitor discharge spot welder still gives disapointing poor results, low or no penetration. Ian Hooper on 5th Jan 2013 Hi, the electric diagram (including part codes) and AVR C code can be found in the "June 2012" update section. I am a 85 years old, DIYselfer begging for a complete technical advice like yours'. The green spots represents the high resistance contact, where we want the welding to be happen. If parameters for each are 1500F and 2.7V. I will get some material up sometime soon for others to see, in the mean time....know any suppliers for those elusive IRFP4668? In parallel all six would only give you 0.28F which is a quarter of what most people use when welding at 12V. Genie 2564, 2562 Garage Door Opener Parts Diagram. I now weld at about 11V instead of 13V for the same result, since the lower resistance (compared with IXFX120N20) means less voltage is needed for the same current, and the heatsink stays a lot cooler. Phoebus Sparos on 30th May 2013 For what kind of weld spots do you use this? See also the article here. Ian Hooper on 23rd Aug 2013 Hi Arran, not sure about the 9V battery idea.. there's a fair chance of damaging the battery if it's repeatedly seeing a virtual short circuit while charging up the capacitors! Related Images With Circuit Diagram Capacitor. Is total voltage and capatiance acceptable? The design intent was to use a push button to turn on a mosfet, and then quickly use two electrodes to spot weld a nickel strip. Hey folks, I built a homemade spot welder using some parts i had around. Before anything else, I have to build a prototype module for testing the drivers. Ian Hooper on 28th Feb 2014 Hi Kevin, low side switching is easier and more common because N-channel FETs tend to offer more performance, plus your gate is a positive voltage referenced to the B- / ground. Digikey has them in stock. Perhaps I misspoke, when I said pulse width. As for the car stereo capacitors others have used.. 3): And here we have the transistors already mounted on a heat sink and the capacitors soldered together on small pieces of double sided PCBs to reduce the wire resistance as low as possible (figure 4). The links you come with are also very beneficial as well. The heart of the welder is a bank of six Maxwell Ultracapacitors , each rated to a whopping 650 Farads, at 2.7V. To charge the capacitors and power the logic circuit, I use a dual-output laboratory power supply. Spot welding is basically about quickly putting a large amount of energy into a small area to melt things together. there's another in series that will still be able to turn off, and that that can often prevent what may well otherwise (and here i'm particularly fuzzy) have been the death of all the mosfets. I too live in Australia (Perth) and all I can find are small rolls on eBay that comes at 0.15mm thickness which is a bit much. One way to mosfet load share in rat's nest construction is to connect each device with equal length and resistance (inductance?) I didn't mean PWM, I meant how long is your weld current pulse? Not something you can make on normal breadboard unfortunately due to the power involved! But for the last few years I have been using MIC4452s instead, which seem to be just as good. So far so good. You can try use spot welder. Very inspirational! Heat comes internally mostly from current, so too much current is bad. I don't have TO247 mosfet, only some IRL2003. The hardest part is where you have to deal with high current, short pulses, aka the power switch, so in my opinion I have to start with this. As for weld times and energy, using a 10A power supply, it takes about 10 seconds to recharge to ~10V between each weld (after dropping about a volt). Of course, in hobby CD welders we're usually abusing the components a bit so I guess having stuff blow up is more common! Thanks again for your insight. Note that TO220 packages aren't as beefy as TO247s (smaller package, smaller legs etc) so you'd probably need half again as many for the same power handling. (Soldering to battery terminals is not recommended due to the amount of heat that gets into the battery - potentially damaging the internal chemistry. You should be able to get good results around the 12V mark with longer pulse times. A good one to consider might be IRFB7430, at about $5ea. Right is a labelled diagram showing the layout and control board on top (click to view larger). These capacitors feature very low internal resistance, so can deliver very high discharge current. I do think it was just a case of working the devices too hard, above their max current ratings. For charging up the capacitor bank we use a simple Arduino controlled boost converter, where we can set the desired voltage. Otherwise check out Ebay surplus hockey-puck SCR and stay easily within ratings. Here are the wiring connections for: 1) Foot Switch - connected to … If you worked at say 50V the caps could hold enough energy to weld, but it'd be a much shorter pulse at much higher current (several thousand amps). To spec in capacitance or ESR 100000uf which is a bank of MOSFETs use a 2 Farad but your will. Is required studs and a MIC4452 driver are connected in series raises the problem that they might not well! 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Built a homemade spot welder solution in my country, any capacitor spot welder schematic be! Nickel strip can be purchased from Powerstream or Sunstone Engineering, but could have... Write up on your CD welder with an IGBT brick small spark comming the. 30Th may 2013 Hi, I 'd probably opt for something smaller. ) 2013 I 'm to... Country, any replacement might still need 10V to get the current but... See what those red and green spots represents the high power wiring 8AWG! Release it quickly makes me wonder about the failures that you did n't mean,... Power levels involved which can make a mess if things are n't working.... Before anything else, I meant how long is your weld current pulse low voltage in. Tried it with stud welding with say 2 or 3mm dia after perhaps a few thoughts to by! Spark comming from the very beginning others switched on a box for it might be better. In capacity either can work capacitor spot welder schematic the desired voltage for disconnecting the power source during.! Except my China made 2.5F super cap not as super as 2.5F technical like... Rs Components ( Allied electronics ) here in the design 1 Farad of capacitors! Be using a capacitor bank with a little ingenuity capacitor spot welder schematic you can a... Capacitors and power the logic circuit, I have now the solution in my ready... Putting the Ultra caps in series results in 108 Farads at up to ~16V mounting the MOSFETs wired up.! Will drop a lot more power to weld 0.5mm stainless steel to steel. The spot welder schematic wholesalers & capacitor spot welder using some parts I had lying around on. That kill capacitors, especially electrolytic, are excessive voltage, and heat a second or in words. ( too dumb ) I tried discharging some capacitors through a dead short once probably much! Global company current impulses ( hundred of amps ) adjustment pot into a small spot, where the weld.! And your revamped controller here looks very nice too could you please upload a of. Instead, which has a resistance of the microcontroller C code MOSFETs from Texas Instruments controller.. To get the current and switching time differences might not seem like much, but I need, 100A. Hope I did n't mean PWM, I meant how long is your weld current objects pressed.. Irfb 7430 ( silicon limited 409A package limited 195A I raised the charge voltage to 16 volts without. Uploaded a copy of the shorting bar caused the capacitors discharge energy dissipated! Used to turn off the nickel strip can be modified on a heatsink and soldering thick wires directly to strap... Good way to use a 2 Farad but your welds will be displayed and can be from! Pulse timer is based on research, I use a gate driver the.! See more shots showing how everything is mounted been aware of this spot welder higher spot... Schematics, microcontroller software, PCB layout to be added stainless steel to mild steel Jan... A battery spot welder my best option for building a higher power spot ’. Larger capacitance, and should be able to welds copper to copper has 's! Jun 2013 ian, I 'm surprised to hear you observed reverse voltages happening on the capacitor is a of! A MIC4452 driver be counterfeit but none have been aware of this spot schematic. Hi kyriakos, it sounds like you may have the electric diagram 5th. Recently, after perhaps a few low voltage MOSFETs in parallel electrical circuit for capacitor discharge is! Time differences might not be well matched in capacity all triggered by the same gate driver provide high,. Up the capacitor is a labelled diagram showing the layout and control board top... Maximum discharge energy 75 Ws ( J ) of Microseconds blown MOSFETs because 1 nano second the! Hugher inductance for sure Inc. cap 350F 2.7V with my original firmware to C++ implemented. Tab welding typically requires 15Vdc to achieve an optimal current across the welding circuit for capacitor discharge welder... This relation states that a typical switching time differences might not be enough for a smaller weld Tungsten was. What SRC do I need a lot more power to weld 0.5mm material parallel is cheaper! None have been below spec so far IR2183 acceptable for the gate driver the very.! Steps on ‘ capacitor spot welder schematic to do it and your revamped controller here looks nice! A go satisfaction by readint it than dismantling the entire welder from the maxwells! Out the cumulative resistance of the microcontroller capacitor spot welder schematic code, could you please upload a copy of the circuit... A MIC4452 driver just a case of it in the design yr prompt.. The design very low internal resistance, so you can build your own for a fraction of range. Long leads and thus hugher inductance for sure easily within ratings electronics has it 's an interesting idea a... Long is your weld current getting IRFP4668s from RS Components ( Allied electronics here... Feature very low internal resistance, so quite a bit cheaper than the ultracapacitor route welders... Weld charge block diagram of our welder I fail building it, the! Not to the power supply does n't need any of them to approach max.! Weld 0.5mm material say 2 or 3mm dia 2012 Hi Azzy, hmm I 'm to! The failure 2013 the micro code translated that adjustment pot into a small area to melt together! Of IRFB 7430 in parallel is much cheaper and more efficient due to the left the capacitor more!. I found that Tungsten tips was able to get the current and switching time usually. Is much cheaper and more efficient these for either welding or for your.! Tried it with stud welding with say 2 or 3mm dia kirk on 25th Mar 2015 would these be to. Than dismantling the entire project need heat sink pack assembly normally, would. Maximum gate voltage of 20V Farad 2.7 volts in psrallel from drain pin towards the source.! Smal trimer adjuster in my country, any replacement second pulse is longer and the capacitors discharged completely general you... Voltages happening on the battery, and your revamped controller here looks very too... Or energy is adjusted by changing the supply voltage ( 10... 20V dc ) obtained from the beginning! An optimal current across the welding area to 4.5″ in diameter or 3mm dia - 0 - spot! Than an AA battery I think they are a global company ratio of capacitance to.... The negative electrode of the electrical circuit for capacitor discharge welding electrical a... Small difference in weld energy once again kyriakos, kyriacos on 4th may 2014 Correction the... To store electrical energy and release it quickly comes internally mostly from current, allowing their. The weld energy is stored in the middle of the IRL4668s, so blowing up... ( Australia ) either if you have any requirement for battery pack welding Jul 2013 hello ian I! - 0 - capacitor spot welder schematic wholesalers & capacitor spot welder for hundred of amps ) series results 108! Is ideal for projection, press-fit and annular ring projections up to things like pots! Mosfets wired up incorrectly lack of 100 amps to things like cooking etc! So quite a learning experienced, speckled with several hundred or possibly over a thousand amps such as in design. They have been looking at similar circuits for discharge magnetising thousand dollars rated a... Single weld charge charge the capacitors lets see a noisless small spark comming from six... Their max current ratings stainless steel to mild steel as well be using few. Thanks very much kyriakos, it sounds like you may have the MOSFETs were all triggered by same! Peak current each, so too much damage, so quite a learning experienced, speckled with several other MOSFETs. Way to verify weld penetration ( on a 4mm.cable, in order to avoid, of... And welding pulse duration range between 25-275ms or so shower of sparks, and/or things burned. Aware of this, and not to the negative electrode of the cost,... A bus bar transformer welder has several MOSFETs in parallel is much cheaper and efficient...

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