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.
How, what are the flat bars connected to each other?
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. Tinning reduces the conductivity of the junction. The protection of the joint against oxidation can be done with pastes or finally by soldering. I still have a note for use in current brass circuits. Overall - great, few words and a lot of examples to follow.
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 motors - transformers. A lot of inquiries about transformer outputs, how they are made (riveted + soldering or hard soldering with silver alloy) in the photos shown. Today I am realizing another transformer order. The dimensions of the windings are 16 mm x 1.50 mm, ie 24 mm2.
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, I weld the packages perfectly, something amazing what the power of this transformer is after winding it to copper tape.
This man knows what he is doing, he has extensive experience in the construction of welding machines, as far as I know from my colleagues from the forum, even Chinese SUNKO do not have a connection to his welding machines.
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 on the winding. I myself 900 W cores (700 W skipping) wind 6 cores. grounding wire 25 mm2, packing it very tightly, practically pressed on a square (on wd40 I think that an interesting modification going further in this direction would be to wind the winding with a copper flat bar with a square cross-section, as in a transformer soldering iron.
Minor disadvantages I notice: - the coil is made of several sheets, yes, touching each other, but with such currents, shouldn't they be more of a monolith? I know, it is used to wind the coils with several wires, but when we fight for every amp ... - a colleague cut the core to mount the winding. OK, I'm assuming flex. Now, in order for the magnetic flux in the core to be as high as possible, it would be optimal to weld / weld the core. Every bit of air on the contact surface of the cut-out exponentially increases the magnetic field losses, i.e. the efficiency of the transformer.
But summing up the profits and losses, I think that the device made in this way has a higher efficiency than the Sunkko 797 - for comparison, it uses a 700 W core and a 16mm2 wire winding.
Question to a colleague: What is the cross section of a single sheet coil and how many rolls are there?
Ps: in my 900 W set with the same programmer, the welding parameters: 0.12 mm steel-nickel plate - t1 = 08 I1 = 67 t2 = 05 i2 = 20 Steel-nickel plate 0.2 0mm - t1 = 10 i1 = 80 t2 = 05 i2 = 20 With a thinner plate, it even applies a single pulse, which is sufficient.