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Cell welding machine on Chinese DIY driver

kulek855 24900 21
This content has been translated » The original version can be found here
  • Hello
    I would like to present for evaluation, possibly to indicate errors and defects of my cell welding machine.

    I do not have access to professional tools, so the housing looks like it looks. It is made of metal sheets left over from a microwave oven, the front part is made of plywood because of easier processing.

    What should be changed in it:
    - convert the cable from 25 mm2 to 35 mm2
    - press the ring terminals with a hydraulic press
    - replace aluminum elements with copper ones in the handle with electrodes

    Initial parameters:
    1300 W transformer
    Secondary winding cross-section 25 mm2
    The voltage of the secondary winding is 3.3 V
    Short-circuit current on the secondary winding 750 A (the meter has a scale of up to 600 A)
    The 40 A driver and electrodes were purchased on aliexpress.

    Current parameters:
    Secondary winding voltage 5V
    Short circuit current on the secondary 910 A


    A video showing the production of the welding machine:

    Link


    Photos of the welding machine:
    Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver

    To make the handle of the welding machine, I used aluminum flat bars, dedicated welding electrodes, springs, screws, OSB and plastic.
    Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver

    The inside of the welding machine
    Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver

    I temporarily insulated the side wall of the welding machine with paper (probably barley) before any contact with the controller.
    Cell welding machine on Chinese DIY driver

    Update 9/11/2020.

    Today I made modifications to the welding machine. The insulation was stripped from the 25 mm2 wire, instead I used two layers of Kapton tape and paper insulation (probably barley). Thanks to this, a few more turns came in and the voltage increased to 5 V.
    Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver

    Update 10/11/2020.
    I have assembled everything, the result is 910 A. All that is left to do is to make electrode handles and the project is completed.
    Cell welding machine on Chinese DIY driver

    Cool! Ranking DIY
    Can you write similar article? Send message to me and you will get SD card 64GB.
    About Author
    kulek855
    Level 11  
    Offline 
    kulek855 wrote 189 posts with rating 41, helped 0 times. Been with us since 2008 year.
  • #2
    Darek05
    Level 11  
    Hi
    Pretty decent execution,

    - how do the seals come out?
    - what are your welding times, number of pulses?

    I will add right away that your output voltage is too low, I recently finished my welding machine and did another one, for a friend and brother, for each of them after the first tests, where I wound the transformers with a 50 mm2 cable (I managed to insert 2 to 3 turns) , it turned out that the seals came out very poorly, the vast majority of them were not successful at all.
    Adjusting the welding time did not bring any good, increasing the welding time actually burned through the lamellae. 0.2 mm and links.
    The output voltage was then in the range of 2-3 V.
    The solution to this problem was to raise the voltage of the secondary winding to the level from 4 V to 5 V, currently I have 4 coils wound, the wire is 25 mm2 and the output is 4.3 V - each weld is perfect, pre-pulse time 10 ms, welding time 60 ms and regardless of the nickel or nickel plates used.

    For example, the upper welds 60 ms, lower 40 ms, welded plates 0.2 mm nickel plated.
    Cell welding machine on Chinese DIY driver
  • #3
    radomski99a
    Level 9  
    From this you should get at least 900-1100 A. There are many mistakes here, but the best way is to look for yourself rather than ask for advice. I have been building my welder for over 1.5 years, perfecting every detail.
    By searching, you gain experience.
  • #4
    kulek855
    Level 11  
    Darek05 wrote:
    - how do the seals come out?
    - what are your welding times, number of pulses?

    The welds at 0.15 mm nickel plate come out nice for me, that's what I use.
    1 pulse, time 0.2, I set the welding power to the maximum value. Yes, realizes that the voltage is low. When I need more power, I will replace the cable with a longer or thicker one, of course without insulation, as mentioned below.


    I do not have photos, but if you are interested, I put a link to the video in which I weld the package to the screwdriver:

    Link



    radomski99a wrote:
    There are many mistakes here

    I'm only interested in security bugs, but I'm open to any feedback anyway. The power of the nickel plate welder is sufficient, if I want to weld nickel, I will replace the cable for 35 mm2, wrapped with Kapton tape + glass fiber tube. Please note that my mediocre, as mentioned above, has a scale of up to 600 A, so I cannot say to what extent the result above 700 A that he indicated corresponds to reality. best regards
  • #5
    dariuszw4
    Level 11  
    Nice layout, nicely made, I made a welding machine myself, but I went the simpler way, my control system consists of exactly 10 electronic components, smooth pulse time adjustment using a sliding resistor, the system is functional, works flawlessly and is without reservations.
  • #6
    kulek855
    Level 11  
    If it works and it works without failures, that's fine.

    Thanks for the opinion.

    So I quickly checked the new electrodes:
    Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver
  • #7
    KrRis
    Level 12  
    I have a question: how did you record a video on YouTube that you can see everything how you work? A webcam on the head or what? Best regards and congratulations on a successful project.
  • #8
    kulek855
    Level 11  
    Thanks. The key here are two photo bulbs placed on tripods. Sometimes I put on softboxes, they give a better effect.
    I shot the film with the Redmi 6 phone placed on a photo tripod. Regards too.
  • #9
    KrRis
    Level 12  
    Well, this video came out very well and professionally, it's nice to watch. I asked because I would like to start having fun with filming my work and uploading it to my website (or YouTube, in fact). You can write down what kind of tripod you used (I know it's off-topic, but if you can ask, I'll be grateful).
  • #10
    kulek855
    Level 11  
    KrRis wrote:
    You can write down what kind of tripod you used (I know it's off-topic, but if you can ask, I'll be grateful).


    I used the Triopo GX-1127 Carbon with the Triopo B2 head and a phone mount for a few zlotys.
    You can safely use a cheap tripod - it does not matter when you are on the phone. I have the following lighting (two such sets):
    Link
  • #11
    radomski99a
    Level 9  
    See here the same driver with pure nickel 0.2 mm thick, the welding machine is able to weld any number of plates. Now I'm waiting for copper. I want to weld copper plates 0.2 mm.
    https://youtu.be/rtQBvazCI18
  • #12
    SylwekK
    Level 31  
    Darek05 wrote:
    I will add right away that your output voltage is too low

    I will add that you are not truthful ;-) If you don't believe me, I invite you to see my design. Link at the bottom in featured.
  • #13
    radomski99a
    Level 9  
    SylwekK, do you weld anything other than a nickel-plated plate? With pure nickel, the higher the tension, the better the welding.
  • #15
    radomski99a
    Level 9  
    I meant welding to cells. There, either nickel-plated steel or almost pure nickel is used (almost, because the nickel content is 99.6%), it is about the shortest possible welding time. I am welding nickel with a time setting of 20-40 ms. I know from experience that the higher the voltage, the better the welding.
  • #16
    Darek05
    Level 11  
    SylwekK wrote:
    Darek05 wrote:
    I will add right away that your output voltage is too low

    I will add that you are not truthful ;-) If you don't believe me, I invite you to see my design. Link at the bottom in featured.


    Maybe so, but in your construction the length of the cables leading to the electrodes has been reduced to the necessary minimum and the 2.9 V looks that it is enough. In my welding machine it did not work, even though I initially had a 50 mm2 wire, it was the same in the other two, which I made in parallel. I would like to add that the electrode cables initially brought out were also 50 mm2. Raising the voltage to 4-5V solved my problems and others. To illustrate the design differences, I enclose photos of my welding machine, currently the electrode wires are 25 mm2 due to its high flexibility, 50 mm2 was too stiff.

    Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver Cell welding machine on Chinese DIY driver
  • #17
    SylwekK
    Level 31  
    @ radomski99a, see the bottom of the post. Nickel-plated sheet (i.e. the most popular). The lowest parameters that I can set, i.e. 10ms / 10ms, create a durable and nice weld.
    https://www.elektroda.pl/rtvforum/viewtopic.php?p=17903368#17903368

    @ Darek05, such a formal question - did you take out this unnecessary core with luck? I am asking because not all remove it and later complain of poor performance.

    Darek05 wrote:
    but in your construction the length of the cables leading to the electrodes has been reduced to the necessary minimum and the 2.9V looks that it is quite enough

    I have an additional module with wires like in a free welding machine, a total of about +80 cm - I do not see a difference in power.
  • #18
    Darek05
    Level 11  
    Quote:
    [...] @ Darek05, such a formal question - did you take out this unnecessary core with luck? I am asking because not all remove it and later complain of poor performance.


    Yes, I blew inductive bridges.
    It is possible that the welding sockets used are an effect of this.
  • #19
    Block3r
    Level 13  
    I was interested in this driver from Aliexpress. Is there a fundamental difference between the 40A and 100A versions?
  • #20
    kulek855
    Level 11  
    Block3r wrote:
    Is there a fundamental difference between the 40A and 100A versions?

    In a single-phase network, 40 A is more than enough.
  • #21
    Block3r
    Level 13  
    I guess so, because I have a 25 A protection. I meant that Chinese products often do not keep parameters - this 100 A will probably last longer.
  • #22
    mmaker
    Level 19  
    Hi, I also made such a welder for cells and after a minor modification, consisting in removing the inductive bridges from the transformer, I have an output voltage of 2.7 V (35 mm2 wire ;) . At 10ms / 10ms pulses, beautiful welds come out, practically like factory ones, it is impossible to tear the plate without damaging it. I use a 10mm / 0.2mm plate.
    Housing made of inverter welding machine, electrodes made of copper wire 4 mm.

    Cell welding machine on Chinese DIY driver