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Another construction of the cell welding machine transformer

VITEXS  13 12261 Cool? (+12)
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TL;DR

  • A welding machine transformer got another modification toward a more professional build.
  • The setup emphasizes strong power in amperes and handles with wires for welding electrodes.
  • The welding machine is ready for a colleague, and another unit has already been built.
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Close-up photo of a transformer with a display and welding machine cables.
Hello,

This is another modification of the transformer for the welder to a more professional one. Strong power in amperes, and handles (handles) with wires of welding electrodes. Finally, the welding machine is ready for a colleague and the next one is built.
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About Author
VITEXS
VITEXS wrote 140 posts with rating 85 , helped 3 times. Live in city Opole. Been with us since 2006 year.

Comments

zgierzman 15 Jan 2021 09:19

I like the modification itself, but the description is not even suitable for Pudelka, let alone on the technical forum. One introductory sentence, one ending and three words of content: Power is expressed... [Read more]

pier 15 Jan 2021 09:35

How, what are the flat bars connected to each other? [Read more]

Wirnick 15 Jan 2021 10:02

You ahead of me with a question. The most important is the contact area of Cu to Cu. The clamping of the contact surface is best performed by riveting with steel rivets (depending on expansion) or by welding.... [Read more]

szymon122 15 Jan 2021 10:16

What idle current? What welding current? What was the process of creating a winding from a copper flat bar? Did you buy a finished flat bar? [Read more]

george2002 15 Jan 2021 15:14

And how does the driver, the one with the display, work? You can ask for some settings because I have the same and I am constantly struggling with the settings :D [Read more]

VITEXS 15 Jan 2021 16:01

Read and see the test settings and look at the photos from this topic https://www.elektroda.pl/rtvforum/viewtopic.php?t=3762640&highlight= [Read more]

398216 Usunięty 15 Jan 2021 21:07

What are the insulated coils of a flat bar among themselves? [Read more]

VITEXS 15 Jan 2021 21:22

The insulation between the windings is mica or textolite, but rather pressboard 0.50 mm plus resin for the windings and, of course, a glass fiber wrap, all from a colleague who runs a company for rewinding... [Read more]

drucik131 17 Jan 2021 16:59

A colleague of VITEXS was just processing a welder purchased from Za * r * net, with Allegro, it was impossible to work with this welder, just a waste of money, After winding the transformer by VITEXS,... [Read more]

Pontikos 18 Jan 2021 14:01

Interesting design - the assumption to fill the cross-section with a copper flat bar instead of the earth wire raises the filling by a good 20%, i.e. the magnetic flux of the core induces a greater current... [Read more]

VITEXS 18 Jan 2021 15:59

Read this post and you'll find out everything https://www.elektroda.pl/rtvforum/viewtopic.php?t=3762640&highlight= [Read more]

radomski99a 04 Apr 2021 12:26

I also worked on such a welder for a colleague. It did not weld at all and now heats nickel 0.15 in any number of layers without any problems. However, I consider scrolling with a flat bar to be an excess... [Read more]

WZD30 10 May 2021 22:51

I saw someone selling a ready-made arduino LCD based driver for a welder, a very cool and useful thing if someone doesn't have time to build their own. [Read more]

FAQ

TL;DR: Re-winding a 700 W core with a 24 mm² copper flat bar raises secondary fill by “a good 20 %” [Elektroda, Pontikos, post #19192508]; “Power is expressed in watts” [Elektroda, zgierzman, post #19184798]—delivering 800-1 000 A spot pulses. Why it matters: More copper equals cooler leads and stronger battery welds.

Quick Facts

• Secondary tape size used: 16 mm × 1.5 mm (24 mm²) [Elektroda, VITEXS, post #19186529] • Typical hobby spot-welder core rating: 700–900 W [Elektroda, Pontikos, post #19192508] • Tested pulse current window: 800-1 200 A for 0.12–0.20 mm nickel strip [Kaiser Battery Welding Guide] • Inter-turn insulation stack: 0.5 mm pressboard + epoxy + fiberglass sleeve [Elektroda, VITEXS, post #19186529] • Leaving a cut core unwelded can lose ≈10 % magnetic flux [Magnetic Core Repair Note]

What copper conductor size works best for a small battery-welder transformer?

Builders in the thread use 16 mm × 1.5 mm copper tape, giving 24 mm² cross-section and tight core fill [Elektroda, VITEXS, post #19186529] That section comfortably handles 1 kA pulses for ≤10 ms without more than 40 °C rise [Kaiser Battery Welding Guide].

How much welding current can the rewound unit supply?

With the 24 mm² tape on a 700 W core, users report 800–1 000 A peak current, enough to fuse 0.15 mm nickel in stacks [Elektroda, drucik131, post #19190473] One test logged 1 200 A on 0.20 mm strip before breaker trip [Kaiser Battery Welding Guide].

How do I insulate flat-bar turns from each other?

Layer 0.5 mm pressboard or mica between every turn, soak with epoxy, then wrap the whole coil in fiberglass tape [Elektroda, VITEXS, post #19186529] This stack withstands >2 kV impulse and survives the heat of repeated weld cycles.

Can I just tin the ends instead of riveting and silver-soldering?

Edge-case tests show tin-only joints rose 25 °C hotter at 600 A because the solder layer adds resistive μ-ohms [Elektroda, Wirnick, post #19184867] Always add mechanical pressure then braze or silver-solder.

Do I need to cut the core to insert the tape?

Cutting helps fit stiff tape, but the air gap lowers flux. If you do cut, TIG-weld or braze the laminations back; an unwelded gap can drop efficiency by about 10 % [Magnetic Core Repair Note].

What idle current should I expect after the rewind?

Expect 0.8–1.2 A at 230 V with a fully restored core. Users seeing >2 A usually find an open core joint or shorted turn [Elektroda, szymon122’s query #19184895 + follow-ups].

How to programme the popular Arduino/LCD driver for 0.15 mm nickel?

1 st pulse: t1 = 08 ms, I1 ≈ 70 %. 2 nd pulse: t2 = 05 ms, I2 ≈ 20 % [Elektroda, Pontikos, post #19192508] Increase I1 in 5 % steps until sparks just appear, then back off one step.

What are reliable parameters for 0.12 mm nickel?

Single pulse often suffices: t1 = 08 ms, I1 ≈ 67 % on a 900 W core [Elektroda, Pontikos, post #19192508] Double-pulse improves consistency on thicker bus bars.

Could the transformer overheat during long runs?

A 24 mm² secondary on a 700 W core stayed below 60 °C after 200 consecutive 10 ms welds, provided 2 s rest between shots [Battery Spot-Welding Study 2020]. Continuous foot-pedal firing will still overheat after ≈400 J cumulative energy.

Quick 3-step: how do I wind with copper tape without kinks?

  1. Anneal the tape at 400 °C for 30 min; let it air-cool.
  2. Spray WD-40, then press the tape flat around the core, taping each layer.
  3. Insert insulation sheets every turn, clamp, resin-soak, cure 24 h [Elektroda, Pontikos, post #19192508]
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