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Safe Switching Circuit for Capacitor Discharge in 250VDC Jewelry Spot Welder Project

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  • #31 21660527
    Steve Lawson
    Anonymous  
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  • #32 21660528
    Sarah Harris
    Anonymous  
  • #33 21660529
    Sarah Harris
    Anonymous  

Topic summary

The discussion centers on designing a safe and user-friendly switching circuit for discharging a charged capacitor at up to 250VDC in a jewelry spot welder application. The main challenge is to enable instantaneous switching at the weld point to ensure the leads become live only during the short circuit, minimizing shock risk. Proposed solutions include using P-channel and N-channel MOSFETs as switches triggered by contact resistance, with considerations for voltage range (70V to 250V) and current handling capabilities. The difficulty in sourcing suitable P-channel MOSFETs led to exploring N-channel alternatives and polarity reversal via opto-isolators for isolation and control. SCRs (thyristors) were also considered due to their cost and surge current capacity, with analysis of their slower switching speed and higher power dissipation compared to MOSFETs. Practical issues such as capacitor longevity under repeated shorting, the use of photoflash capacitors, and the possibility of capacitor banks switched sequentially by a 4017 decade counter were discussed to improve refresh time and welding frequency. Additional circuit elements like voltage indicators (10-LED bargraph), latching circuits for inverter control, and footswitch alternatives were evaluated. The importance of proper gate drive, polarity, and current limiting components (diodes, resistors) was emphasized to ensure reliable operation and safety. References to educational resources on MOSFET operation and circuit simulation tools (CircuitWizard) were provided to aid understanding. Overall, the conversation highlights the trade-offs between component availability, electrical characteristics, safety, and user ergonomics in developing a capacitor discharge switch for high-voltage spot welding.
Summary generated by the language model.
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