Nowadays it is difficult to imagine any work with the metal without the use of the welding machine. With this device, you can easily connect or cut iron of various thicknesses and dimensions. Naturally, you will need certain skills in this matter to fulfill quality work, but first of all you need a welder. In our time, it can naturally buy it, as in principle and hire a welder, but in this article we will talk about how to make the welding machine with your own hands. Moreover, with all the wealth of various models, reliable is quite expensive, and cheap do not shine quality and durability. But even if you decide to buy a welder in the store - familiarity with this article will help choose the necessary device, since you will know the basics of their scheme engineering. Wellers are several types: DC, variable, three-phase and inverter. In order to determine which option you need, consider the design and device of the first two types, which can be applied without specific skills at home.
On alternating current
This type of welding machine is one of the most common options, both in industry and in private farms. It is easy to operate, compared to the rest, it is quite easy to do at home, which confirms the photo below. To do this, you need to have a wire for primary and secondary windings, as well as a core of transformer steel for winding a welder. Simple words, the AC welding machine is a lower transformer of high power.
Optimal voltage when working with a welding machine, assembled at home - 60V. Optimal current 120-160A. Now it is easy to calculate what section should have a wire in order to make the primary winding of the transformer (one that will connect to the 220 V network). The minimum cross-sectional area of \u200b\u200bthe copper wire should be 3-4 square meters. mm, the optimal is 7 square meters. mm, because it is necessary to take into account and possible additional load, as well as the necessary margin of safety. We obtain that the optimal diameter of the copper conductors for the primary winding of the lowering transformer must be 3 mm. If you decide to take an aluminum wire in order to make the welding machine with your own hands, the cross section for the copper wire must be multiplied by the coefficient of 1.6.
It is important that the wires in the rag braid can not be used by conductors in PVC insulation - it is melted when heating the wires and occurs. If you do not have the wires of the required diameter, you can use thinner veins, winding them in parallel. But then it should be borne in mind that the thickness of the winding will increase, and the dimensions of the device itself will increase. It should be borne in mind that the limiting factor may be a free window in the core and the wire may simply not fit there. For the secondary winding, you can use a thick multicore copper wire - the same as it lived on the holder. Its cross section should be chosen based on the current in the secondary winding (we recall that we are focused on 120 - 160a) and long wires.
First of all, it is necessary to make a core of the transformer of the self-made welding machine. The optimal version will be a core type core as shown in Figure 1:
This core must be made from transformer steel plates. The thickness of the plates should be from 0.35 mm to 0.55 mm. This is necessary to reduce. Before collecting the core, you need to calculate its dimensions, this is done as follows:
- First, the magnitude of the window is calculated. Those. Sizes C and D in Figure 1 You must choose to place all transformer windings.
- Secondly, the area of \u200b\u200bthe roll, which is calculated by the formula: SCREN \u003d A * B, should be at least 35 square meters. See if SKREN is larger - then the transformer will heat up less and work longer accordingly, and you will not need to be completely interrupted so that it is cooled. It is better that SCRENA is 50 square meters. cm.
Next, proceed to the assembly of the plates of the self-made welding machine. It is necessary to take M-shaped plates and fold them, as shown in Figure 2, until it turns out to make the core of the required thickness. After that, we fasten it with bolts in the corners. At the end, it is necessary to treat the surface of the plates to the surface of the plates and exhibit them, wrapped with rag insulation to additionally protect the transformer from breakdown on the body. 
Next, proceed to winding the welding machine from the lowering transformer. At the beginning, we wake the primary winding, which will consist of 215 turns, as shown in Figure 3. 
It is advisable to make a branch from 165 and 190 turns. Top of the transformer attach a thick textolite plate. The ends of the windings are fixed on it with the help of a bolted compound that the first bolt is a common wire, the second is a branch from 165 turns, the 3rd is a branch from 190 of the turn and the 4th - from the 215th. This will make it possible to subsequently adjust the strength of the current during welding, by switching between different conclusions of your welding device. This is a very important feature, and the more branches you will do, the more accurate you will have adjustment.
After getting up winding 70 and turns of the secondary winding, as shown in Figure 4. 
A smaller number of turns are wound on the side of the core - where the primary winding is wound. The ratio of turns need to be made about 60% to 40%. This contributes to the fact that after you catch an arc and start welding, the vortex currents will partially disconnect the operation of the winding with a large number of turns, which will reduce the welding current, and accordingly improve the quality of the seam. Thus, the arc will be easily causing, but too much the current will not interfere with quality cooking. Winding ends will also be fixed using a bolt on a textolite plate. You can not attach them, but to carry out the wires directly to the holder of the electrodes and the crocodile on the ground, it will remove the compounds where the stress and heating can potentially. For better cooling it is extremely desirable to install a fan for blowing, for example, from a refrigerator or microwave.
Now your homemade welding machine is ready. By connecting the holder and the mass to the secondary winding, you need to connect the network to the overall wire and the wire that departs from the 215th turn of the primary winding. If you need to increase current strength, then you can make a smaller number of turns of the primary winding, switched the second wire to contact with fewer turns. It is possible to reduce the current with the help of the resistance made of the brine made of a curved spring, connected to the holder. It is always necessary to ensure that the welding machine does not overheat, for this, regularly check the temperature of the core and windings. For these purposes, you can even install an electronic thermometer.
In this way, you can make a welding machine from a lowering transformer with your own hands. As you can see, the instruction is not too complex and even an inexperienced electrician will be able to assemble the device yourself.
On constant toke
For some types of welding, a DC welder is required. Such a tool can cook cast iron and stainless steel. Make a DC welding machine with your own hands, you can not more than in 15 minutes, converting self-made on alternating current. To do this, the rectifier collected on diodes must be connected to the secondary winding. As for diodes, they must withstand the current of 200 A and have good cooling. For this, D161 diodes are suitable.
Align the current will help us with condensers C1 and C2 with the following characteristics: Capacity 15000 μF and voltage 50B. Next we collect the scheme that is indicated in the drawing below. The throttle L1 is required to adjust the current. Contacts x4 - plus for connecting the holder, and x5 - minus for the flow of current to the welded part of the part.
Three-phase welding machines are used for welding under production conditions, two-electrode holders are installed on them, so we will not consider them in this article, and the inverters are manufactured based on printed circuit boards and complex schemes with a large number of expensive radio components and a complex setting process using special equipment. However, we still recommend that you familiarize yourself with the inverter design on the video below.
Visual master classes
So, if you decide to make a welding machine at home, we recommend watching video lessons given below, which will clearly show how to assemble a simple welder from undergraduate materials yourself, and also explain to you some details and nuances of work:
Now you know the basic principles of the design of welders and you can make the welding machine with your own hands, both on the constant and alternating current, using the instructions from our article.
Also read:
Welding work at home has long been commonplace. Availability of devices and consumables, the ability to cheap on the courses of welders, various methods for obtaining independent skills. All these factors make it possible to save on the remuneration of professional welder, and increase the efficiency of work.
However, if carefully examine the welding machine market, unpleasant moments are found:
- High-quality welders have a high cost, it is more profitable to hire a specialist several times (if, of course, you are not working constantly).
- Available for the price Aggregates have a number of shortcomings: low reliability, poor weld quality, dependence on the supply voltage and type of consumables.
Hence the conclusion: if high quality equipment is needed at an affordable price, you will have to make a welding machine from available materials with your own hands.
Before considering the options for self-made welders, we will analyze the principle of their work.
The basis of the work of any unit is the law of Oma. With unchanged power, there is an inverse relationship between the current and voltage. For normal operation requires the current of 60-150 A. only in this case, the metal in the welding zone will melt. Imagine a welding machine that works directly with a voltage of 220 volts. To achieve the required current strength, a capacity of 15-30 kW will be required. First, for this it will be necessary to lay a separate line of power supply: most of the inputs in residential premises are limited by technical conditions at the level of 5-10 kW. In addition, for such a strength of the current, the sequence of at least 30 mm² will be required. Cooking will have to comply with the protection measures when working in electrical installations up to 1000 volts: rubber bots, gloves, workplace fence, and so on.
Of course, providing such conditions in reality is impossible.
Therefore, any welding machine converts the voltage (in the direction of the decrease): at the output we obtain the desired current while maintaining reasonable power.
The optimal voltage value is 60 volts. With a welding current of 100 A, it is quite acceptable 6 kW of power. How to convert voltage?
There are four main types of welding machines
Any of the listed devices can be collected independently. We will review the manufacturing technologies on models:
Transformers (with or without rectifier)
The heart of the transformer is the core. It is recruited from plates of transformer steel, which is manually made are quite problematic. True and untrue, the starting material is mined at factories, in construction teams, at scrap metal. The resulting design (as a rule, in the form of a rectangle) must have a cross section of no less than 55 cm². This is a pretty heavy design, especially after laying windings.
When assembling, it is necessary to provide an adjusting screw, with which you can move the secondary winding with respect to fixed primary.
In order not to go into the difficulty of calculating the cross section of the wires, take typical parameters:
- current at the secondary card 100-150 A;
- idling voltage 60-65 volts;
- working voltage during welding 18-25 volts;
- the power of the current on the primary winding to 25 A.
Based on this, the primary wire cross section should be at least 5 mm², if you do with a reserve - you can take a wire 6-7 mm². Isolation should be heat-resistant, from a material that does not support combustion.
The secondary winding is recruited from the wire (and better copper tire), a cross section of 30 mm². Isolation is rag. Let the thickness do not scare you, the number of turns on the secondary is small.
The number of turns of the primary winding is determined by the coefficient of 0.9-1 volt coefficient (for our parameters).
The formula looks like this:
W (number of turns) \u003d U (voltage) / coefficient.
That is, at a voltage in the 200-210 volt network, it will be about 230-250 turns.
Accordingly, at a secondary voltage of 60-65 volts, the amount of its turns will be 67-70.
From a technical point of view, the transformer is ready. For ease of use, it is recommended to perform a small margin on the secondary winding, with several branches (65, 70, 80 turns). This will allow you to work confidently in places with low-voltage network.
Hold the unit into the case, or leave open - this is a matter of use of use. Typical manufactured welding transformer looks like this:
The optimal material for the housing is a textolite 10-15 mm.
Add rectifier
Homemade powerful welding transformer from the point of view of circuitry - a regular power supply. Accordingly, the rectifier works as simple as in the network charge for a mobile phone. Only the element base will look at a few orders of massive.
As a rule, a pair of capacitors are added to a simple diagram from the diode bridge, the pulses of the straightened current.
You can assemble the rectifier and without them, but the greater the current, the better the welding seam is obtained. For the assembly of the bridge itself, powerful d161-250 diodes (320) are used. Since there is a lot of heat in the load on the elements, it must be dispersed with radiators. Diodes are attached to them with a bolted joint and thermal splash.
Of course, the ribs of radiators should either be blown in the fan, or perform over the case. Otherwise, instead of cooling, they will warm the transformer.
Mini welding transformer
If you do not need to boil rails or chapellera from steel 4-5 mm, you can collect a compact welder for the spike of steel wire (making framework for homemade) or a fine tin welding. To do this, you can take a ready-made transformer from a powerful household appliance (the perfect version is a microwave), and rewind the secondary winding. Wire section 15-20 mm², power consumption no more than 2-3 kW.
The calculation of the scheme is also made as for more powerful aggregates. When assembling a rectifier, you can use less powerful diodes.
Microwkeemer
If the scope of application is limited to the spike of copper wires (for example, when installing junction boxes), it is possible to limit the design with a pair of match boxes.
Performed on the CT835 transistor (837). The transformer is manufactured independently. In fact, this is a high-frequency boost converter.
Unlike traditional welders, high voltage is used in this scheme, up to 30 square meters. Therefore, when working should be careful.
The transformer is winding on a ferrite rod. Two primary windings: collector (20 twist 1 mm), base (5 turns 0.5 mm). Secondary (promotional) winding - 500 turns 0.15 wire.
We collect the scheme, we solder the resistor strapping according to the scheme (so that the transformer does not overheat at idle), the device is ready. Power from 12 to 24 volts, with the help of such a device you can weld the harnesses of the wires, cut thin steel, connect the metals with a thickness of up to 1 mm.
As welding electrodes, you can use a thick sewing needle.
Inverter (Pulse power supply for welding)
The homemade inverter welding machine cannot be made simply "on the knee." This will require a modern element base and experience with the repair and creating electronic devices. However, the scheme is not so scary as it is small. There are a great set of such devices, and they all work are not worse than factory analogs. In addition, to create a pulse welding machine with their own hands, it is not necessary to purchase dozens of expensive radio components and finished nodes. Most of them, especially high-frequency elements for the power supply, can be borrowed from old TVs or BP from the computer. The cost is close to zero.
The inverter in question has the following characteristics:
- Load current on electrodes: up to 100 A.
- Power consumption from 220 volts - no more than 3.5 kW (current of about 15 A).
- Used electrodes up to 2.5 mm.
The illustration shows a ready scheme that has been repeatedly tested by many domestic masters.
Constructively, the inverter consists of three elements:
- Power supply for the converter and control circuit. Made on an affordable element database using optocoupler from the old computer power supply unit. With independent production of the transformer, the cost is almost zero: the details are kopeck. Nominal and names of radio elements in the illustration.
- Capacitor charge delay unit (for starting arc). Made on the basis of CT972 transistors (absolutely not a deficit). Of course, transistors are installed on radiators. For switching, a fairly ordinary automotive relay with a current load on contacts up to 40 A. For manual control, ordinary protective automata (bagnits) are installed on 25 A. The output 300 volts - idling. With load voltage 50 volts.
- Current transformer is the most responsible node. When assembling, special attention should be paid to the accuracy of inductance coils. Some adjustment can be performed using an alternating resistor (on the diagram is highlighted in red). However, if the parameters are not consistent, the required power of the arc will not succeed. It is implemented on the US3845 chip (one of the few details that you have to buy). Power transistors are all the same KT972 (973). Some elements on the import scheme, however, they can be easily replaced by the available domestic, searching for the analogues on the Datasheet website. High-frequency block is made of parts of the line transformer from the TV.
Work wires are connected to the output of the welding inverter. No more than 2 meters long. Section of at least 10 squares. When working with electrodes up to 2.5 mm, the drop in the current is minimal, seams turns out smooth and smooth. The arc is continuous, not worse than the factory counterpart.
If there is active cooling (fans from the same computer power supply), the design can be compact in a small case. Given the high-frequency converters, it is better to use metal.
Outcome
The harder the homemade welding machine, the feeling of savings. It is simple transformers that are more expensive, due to the use of expensive copper in windings or transformer iron. Pulse power supplies, especially if there are old parts from typical electrical appliances in the reserve, cost almost free.
Video on the topic
The welding machine cannot be called the first need tool at home, such as a screwdriver or hammer. However, there are situations where the welding machine is really necessary. In this material, we will look at the method of assembling a simple welding machine at home.
We offer first view a video for the manufacture of a welding machine
So, we will need:
- water tank;
- salt;
- water;
- two metal plates;
- wire with a fork;
- two wires;
- Welding electrode.
According to the author of the self-catering, the process of creation takes only 15 minutes, so let's not waste time in vain and go to the manufacture of a self-made welding machine. First of all, we need to take one metal plate and fasten one of the two wires to it.
We repeat the process with the second plate and the second wire.
The next thing we fall asleep into the water two tablespoons of salt and stir good all.
The resulting mixture is immersed by two plates and wires scored on them.
For security reasons, metal plates are advised to fix clothespins.
The plates actually allow you to adjust the welding current. How exactly does it work? The deeper we immerse the records, the more we get the current.
One wire coming from one of the plates, we must connect to the phase, and the second wire to the welding electrode.
Also take the zero wire and connect to the subject that we need to boil.
There is quite a logical question - how can I determine where the phase and where zero, if for some reason there are no special devices for the measurement. There is an old faithful way: you just need to touch the wire to the ground. The wire that will be spoken by touching with the Earth, then the phase is.
The welding machine is a pretty popular device both among professionals and homemade masters. But for household use, there is no point in buying an expensive unit, since it will be used in rare cases, for example, if you need to brew a pipe or put a fence. Therefore, it will be wiser to make a welding machine with your own hands, putting a minimum amount of funds into it.
The main part of any welder operating on the principle of electric arc welding is a transformer. This detail can be removed from old, unnecessary home appliances and make a homemade welding machine from it. But in most cases a transformer requires a small refinement. There are several ways to make a welder, which can be both simple and more complex, requiring knowledge in electronics.
To make a mini-welding machine, you will need a pair of transformers removed from an unnecessary microwave oven. The microwave is easy to find friends, acquaintances, neighbors, etc. The main thing is that it has a power within 650-800 W, and there was a transformer in it. If the stove has a more powerful transformer, then the device will turn out with higher current indicators.
So, the transformer, filmed from the microwave, has 2 windings: primary (primary) and secondary (secondary).
Seconder It has more turns and a smaller wire cross section. Therefore, that the transformer becomes suitable for welding, it is required to remove it and replace the conductor with a larger cross section. To remove this winding from the transformer, it is necessary to cut it on both sides of the part with a metal hacksaw.
It is necessary to do it with special accuracy to accidentally do not touch the saw of the primary winding.
When the coil is a spinal, its residues will need to be removed from the magnetic pipeline. This task will be much eased if drilled windings to remove metal voltage.
Do the same operations with another transformer. As a result, you will have 2 parts that have a primary winding at 220 V.
Important! Do not forget to remove current shunts (shown by arrows in the photo below). This percentage of 30 will increase the power of the device.
For the manufacture of secondary, it will be necessary to purchase 11-12 meters of wire. He must be stranded and have cross section of at least 6 squares.
To make a welding machine, for each transformer, it will be necessary to wind up 18 turns (6 rows in the height and 3 layers in the thickness).
You can braided both transformers with one wire or separately. In the second case, the coil must connect sequentially.
Winding should be made very dense, so that the wires do not hang out. Next, the primary windings need connect parallel.
To connect the details together, they can be screwed to a small cutting of a wooden board.
If measuring the voltage on the secondary of the transformer, then in this case it will be equal to 31-32 V.
This homemade welder is easily boiled by a metal with a thickness of 2 mm electrodes with a diameter of 2.5 mm.
It should be remembered that cooking with such a homemade apparatus follows with resting breaks, since its windings are heated greatly. On average, after each electrode used, the machine must cool for 20-30 minutes.
The thin metal unit made from the microwave will not work, as it will cut it. To adjust the current to the weld, you can connect a ballast resistor or choke. The role of the resistor can perform a segment of steel wire of a certain length (selected experimentally), which is connected to the low-voltage winding.
Variable Tock
This is the most common type of metal welding machines. It is easy to make it at home, and it is unpretentious in operation. But the main disadvantage of the apparatus is large weight of the lowering transformerwhich is the basis of the aggregate.
For home use, it is enough for the device to issue a voltage of 60 V and could provide current strength in 120-160 A. so for PermitTo which the household network 220 V is connected, a wire with a cross section of 3 mm 2 to 4 mm 2 will be required. But the perfect option is a conductor with a cross section of 7 mm 2. With this section of voltage drops and possible additional loads, the device will not be scary. It follows from this that the renewer needs a conductor having 3 mm in diameter. If you take an aluminum conductor, the calculated cross section is multiplied by the coefficient of 1.6. For renewed It will take copper tire with a cross section of at least 25 mm 2
It is very important that the winding conductor is covered with rag insulation, since the traditional PVC shell is melted when heated is melted, which can cause inter-touch closure.
If you did not find the wire with the necessary section, then it can make yourself Of the few thinner conductors. But at the same time the thickness of the wire will significantly increase and, respectively, the dimensions of the unit.
First thing, the base of the transformer is manufactured - core. It is made of metal plates (transformer steel). These plates must have a thickness of 0.35-0.55 mm. Studs connecting plates, it is necessary to isolate well from them. Before assembling the core, its sizes are calculated, that is, the size of the "windows" and the area of \u200b\u200bthe core cross section, the so-called "core". To calculate the area, the formula is used: S cm 2 \u003d a x B (see Fig. Below).
But from practice it is known that if you make a core with an area of \u200b\u200bless than 30 cm 2, then such a device will be difficult to get high-quality seam due to lack of power supply. Yes, and he will be heated very quickly. Therefore, the core cross section should be at least 50 cm 2. Despite the fact that the mass of the aggregate will increase, it will become more reliable.
For the assembly of the core it is better to use M-shaped plates And place them as shown in the following figure, while the thickness of the part does not reach the desired value.
Plates at the end of the assembly need to be copper (at the corners) with bolts, then clean the file and insulate with tissue insulation.
Now you can start winding transformer.
One nuance should be taken into account: the ratio of turns on the core should be 40% to 60%.This means that on the side where the primary is placed, there must be a smaller number of repetitions. Due to this, when welding welding, the winding having more turns will be partially disconnected due to the occurrence of vortex currents. This will increase the strength of the current, which will be positively affected on the quality of the seam.
When the transformer winding is completed, the network cable is connected to the total wire and to the branch of 215 turns. Welding cables are connected to the secondary winding. After that, the contact welding machine is ready for operation.
Constant
To cook cast iron or stainless steel, a DC device is required. It can be made from the usual transformer unit, if it is to its secondary winding connect rectifier. Below is a diagram of a welding machine with a diode bridge.
Welding machine circuit with diode bridge
The rectifier is assembled on diodes D161 capable of withstanding 200a. They must be installed on radiators. Also, 2 condenser (C1 and C2) is required to equalize the pulsation of the current by 50 V and 1500 μF. This electroscheme also has a current regulator, the role of which is performed by the throttle L1. Welding cables (direct or reverse polarity) are connected to x5 and x4 contacts, depending on the thickness of the metal connected.
Inverter from computer power supply
The welding machine from the power supply of the computer is not possible. But use its body and some details, as well as the fan is quite real. So, if you make the inverter with your own hands, it can be easily accommodated in the BP housing from the computer. All transistors (IRG4PC50U) and diodes (CD2997A) must be installed on radiators without using pads. For cooling parts preferably use a powerful fan, such as THERMALTAKE A2016. Despite its small sizes (80 x 80 mm), the cooler is able to develop 4800 rpm. Also, the fan has a built-in revolver regulator. The latter are adjustable using a thermocouple that needs to be fixed on a radiator with installed diodes.
Tip! In the BP housing, it is recommended to drill a few additional holes for better ventilation and heat dissipation. Protection against overheating, installed on transistor radiators, is configured to trigger at 70-72 degrees.
Below is a circuit electrical diagram of the welding inverter (in a large resolution), which you can make the device placed in the BP housing.
The following photos show which components consisting of a homemade inverter welding machine, and as it looks after the assembly.
Welder from electric motor
To make a simple welding machine from the stator of the electric motor, it is necessary to choose a motor itself that meets certain requirements, namely, that its power is from 7 to 15 kW.
Tip! It is best to use the 2a series engine, since it will have a large magnetic pipeline window.
You can get the desired stator in places where the scrap metal is taken. As a rule, it will be cleaned from the wires and after a pair of blows a sledgehammer splits. But if the hull is made of aluminum, then to remove the magnetic circuit, it will be necessary to join the stator.
Preparation for work
Put the stator with a hole up and down under the detail of the bricks. Next, fold inside the firewood and burn them. After a pair of watches, the magnetic pipes are easily separated from the housing. If there are wires in the case, then they can also be removed from the groove after heat treatment. As a result, you will receive a magnetic circuit cleaned from unnecessary elements.
This blank should be fine oily And let her dry. To accelerate the process, the heat gun can be used. The impregnation of varnish is done so that after removing the screeds, the package does not occur.
When the disc will dry out completely using the Bulgarian, remove tiePlaced on it. If you do not remove the screed, they will perform the role of short-circuited turns and take the power of the transformer, as well as cause it with heating.
After cleaning the magnetic pipeline from unnecessary parts, it will be necessary to make two face lining (See Figure below).
The material for their manufacture can serve either cardboard or pressspan. You also need to make two sleeves from these materials. One will be inner, and the second is outdoor. Next, you need:
- install both end linings on the blank;
- then insert (dress) cylinders;
- all this design is wrapped with a migratory or glass bench;
- impust the resulting detail of varnish and dry.
Making a transformer
After the actions described above, a welding transformer can be made from the magnetic pipeline. For these purposes, a wire covered with tissue or glass emal isolation is needed. To wind the primary winding, the wire is required with a diameter of 2-2.5 mm. The secondary winding will require about 60 meters of copper tire (8 x 4 mm).
So calculations are made as follows.
- On the core, the 20 turns of the wire having a diameter of no lower than 1.5 mm should be hosted, after which, it is necessary to submit a voltage on it 12 V.
- Measure the current flowing in this winding. A value should be about 2 A. If it turned out a value of more required, the number of turns need to be increased if the value is less than 2a, then reduce.
- Calculate the number of turns of the turns and divide it to 12. As a result, you will get a value that indicates how much turns are needed to 1 in voltage.
For primary winding Suitable conductor with a diameter of 2.36 mm, which is required to be folded. In principle, you can take any wire with a diameter of 1.5-2.5 mm. But before you need to calculate the cross section of the conductors in the twist. First you need to wind the primary winding (220 V), and then - secondary. Its wire must be isolated over the entire length.
If in the secondary winding, make a removal on the site where 13 V is obtained, and put the diode bridge, then this transformer can be used instead of a battery if you need to start a car. For welding, the voltage on the secondary winding should be within 60-70 V, which will allow the use of electrodes with a diameter of 3 to 5 mm.
If you laid both windings, and in this design there is free space, you can add 4 copper tires (40 x 5 mm). In this case, you will get a winding for spot welding, which will allow you to connect a sheet metal to 1.5 mm thick.
For manufacturing case Use metal is not recommended. It is better to make it from textolite or plastic. In places fastening the coil to the case, rubber gaskets should be paved to reduce vibration and better insulation from conductive materials.
Homemade dot welding
The finished apparatus for point welding has a fairly high price that does not justify its internal "filling". It works very simply, and make it his own will not be a lot of work.
To independently make a point welding machine, you will need one microwave transformer with a capacity of 700-800 W.From it you need to remove the secondary winding in the manner described above in the section where the manufacture of the welding machine from the microwave was considered.
The apparatus for point welding is made in the following way.
- Make 2-3 turns inside the manitoprovod cable with a conductor diameter of at least 1 cm. It will be a secondary winding that allows you to get a current in 1000 A.
- At the ends of the cable, it is recommended to install copper tips.
- If you connect to the primary winding of 220 V, then on the secondary winding, we will receive a voltage 2 V with a current of about 800 A. this will be enough to melt a regular nail in a few seconds.
- Followed by make a housing for the apparatus. A wooden board is well suited for the base, from which several elements should be made, as shown in the following figure. The dimensions of all parts may be arbitrary and depend on the dimensions of the transformer.
- To give the housing a more aesthetic look, sharp corners can be removed using a manual milling with the edge cutting mill installed on it.
- On one part of welding ticks need cut a small wedge. Thanks to him, the ticks will be able to rise above.
- Cut on the back wall hole housing for switch and network wire.
- When all the details are ready and grounded, they can be painted with black paint or to cover with varnish.
- From an unnecessary microwave, you will need to disconnect the network cable and the limit switch. The metal door handle will also need.
- If you have no foot and copper rod, as well as copper clamps, then the details must be purchased.
- Copper wire cut 2 small rods that will perform the role of electrodes, and secure them in the clips.
- Screw the switch to the rear wall of the body of the apparatus.
- Screw to the base the rear wall and 2 racks, as shown in the following photos.
- Secure the transformer based on the base.
- Next, one network wire is connected to the primary winding of the transformer. The second network wire is connected to the first terminal of the switch. Then you need to attach the wire to the second terminal of the switch and connect it to another output of the primary. But on this wire should be taken and install in it microwave. It will execute the role of the welding button. These wires must be sufficient length so that it is enough to place the interrupter at the end of the ticks.
- Secure the device cover on the racks and rear wall with the handle installed.
- Secure the side walls of the case.
- Now you can install welding ticks. First, drill on their ends along the hole in which the screws will be screwed.
- Next, fasten the switch at the end.
- Insert the pliers into the case, pre-putting between them for the alignment of the square bar. Drill in the ticks through the side walls of the hole and insert long nails in them, which will serve as axes.
- At the ends of the ticks, secure the copper electrodes and align them so that the ends of the rods are opposite each other.
- So that the upper electrode is raised automatically, screw the 2 screws and secure the gum on them, as shown in the following photos.
- Turn on the unit, connect the electrodes and click the Start button. You must see the electrical discharge between the copper rods.
- To check the unit, you can take metal washers and weld them.
In this case, the result was positive. Therefore, the creation of a point welding machine can be considered finished.
It is now difficult to see the holding of any work with the metal without the use of the welding machine. This device freely cuts or connects iron parts, regardless of its thickness and sizes. To make welding, you need to have some skills, well, and actually the device itself. You can buy it, you can hire a welder for the necessary work, and you can make the aggregate with your own hands.
Standard diagram of the welding machine and its types
Before creating a welding machine at home, its device should be understood.
The main element of the welder, from which it consists is a transformer that feeds the arc of the device, controlling alternating voltage and controlling the quality and current value.
The design of standard welding machines is very diverse, but these main types can be distinguished:
- AC apparatus;
- Permanent current;
- Three-phase;
- Inverter.
The welding with the use of constant currents is usually used to work with thincase material, automotive and roofing steel.
Distant and AC welding devices are reliable, unpretentious when operating, heavy by weight and very sensitive to voltage drops. If it falls below 200 volts, it will be difficult to work, there will be problems with the ignition and support of the arc.
These welding machines are very similar in their design and if we have alternating current welding, then it is a little modified, we get a device for working with a constant current.
As for the inverters, thanks to the use of electronic parts, their weight has become much easier. They are not afraid of voltage drops, but at the same time very sensitive to overheating. You need to work with such devices carefully, otherwise they can break.
Self-made alternating current welding machine
A variable current welding unit is one of the most common models. It is the easiest to use and easily assemble houses compared to other types of welders.
What is needed for this:
- Wires for the secondary and primary winding;
- Candel for winding;
- A lowering transformer (Latra can be taken).
What kind of wires need? The optimal voltage during the operation of the apparatus created by itself is 60V with optimal current - 120 -160A. Based on this, we understand that the minimum cross-section of copper wires to wind the primary must be 3-4 square meters. mm. Optimal - 7 square meters. mm, which takes into account possible additional load and voltage jumps.
You can not use wires in PVC or rubber insulation, as they can overheat and cause a closure.
If there is no wire of the desired section, you can use fine veins wound together. True, the winding thickness will increase that it will entail an increase in the dimensions of the device itself. To make the secondary winding, you can take a thick copper wire consisting of a variety of lived.
The homemade core is made from the transformer steel plate, the thickness of which should be from 0.35 mm to 0.55 mm. They must be folded so that the core is obtained by the required thickness, and then fix the device with bolts in the corners. At the end of the work, the surface of the plates should be treated with nadfil and make insulation.
Then the winding begins. Initially, primary (you can make about 240 turns). In order to have the ability to adjust the current current, you need to make several taps with an approximate step in 20-25 whots.
How much copper need for the secondary winding? Typically, the number of turns is 65-70. Wire cross section - 30 - 35 sq. Mm. As with primary winding, you need to make taps for current control. Wiring isolation should be reliable and stealing to heat.
The winding is made in one direction and each it is isolated. The winding ends are mounted with bolts to the plate and we can assume that the homemade welder is ready.
If you need to increase the current strength - in this case, a voltoddavod can help or can be done manually, reducing the number of turns of the primary winding and switches the wire to contact with a smaller number of turns.
Creating a welding machine, you need to not forget it to ground, according to safety technique. And also always need to ensure that the welding machine does not overheat!
Simple DC welding machine
For the welding of cast iron and stainless steel, you will need a constant apparatus. It is possible to create it in 15 minutes if there is a device on alternating current. In this case, an existing device will be upgraded.
The alteration of the change will be connected to the rectifier's secondary winding, which is assembled on diodes. Diodes should in turn, to withstand the current in 200 A and cool well.
The rectifier will be better cope with its work if you use capacitors with a voltage of 50V and a special throttle to adjust the current.
What you need to know by connecting the device to the network for constant:
- Be sure to use the switch, which at any time can turn off the device from the network;
- The wire cross section for the connection should be greater than or equal to 1.5 square meters. mm, and consumption current in the primary winding - maximum 25 A.
The scheme of the welder is such that he is from time to time to relax. And it does not matter the semiautomat is, or the handbrake. However, if the device operates on electrodes with a diameter of less than 3 mm, then you can not interrupt.
Inverter: how to make a welding machine with your own hands
Alone the inverter can be collected from small parts and wiring from the Soviet TV or vacuum cleaner.
Features of the inverter:
- The device works with a constant current and its smooth adjustment from 40 to 130 A;
- The largest current for the primary winding - 20a, the electrodes used should be no more than 3 mm;
- The electric holder must have a button by clicking the voltage to the device.
All elements of the inverter are located on a special printed circuit board, and for better heat removal from diodes, they are fixed on a special heat sink that is screwed to the board. The board itself is usually made from a fiberglass, an approximate thickness of 1.5 mm.
For additional cooling of the circuit, you can use the fan fixed directly to the housing in which the inverter is located.
With the help of such an apparatus, you can safely cook colored and ferrous metals, blanks from a thin sheet.
Three-phase welding machines are usually used for welding in production conditions, so they do not make sense to do their homes.
Wellectrics of Timvala, Budenoi and thyristors are particularly popular.
Tips how to make a welding machine at home: point welding
One of the most convenient and economical mini pans has recently become a point, occurring contact method. In everyday life, such a thing is used to repair household appliances and welding batteries.
Heating occurs with the help of a pulse, and the pulse moment does not exceed one tenth of a second, that is, everything happens very quickly.
It creates such a minisman using a transformer from the old microwave, which will be refined in the process of creating the machine. The goal is the ability to get a short-term impulse at no less than 1000a.
Refinement occurs in this way:
- From the transformer, everything except the core and the primary winding is removed;
- The wire with a cross section of no less than 100 square meters is wedge into place of the secondary winding. mm;
- Here the main thing is very tightly winding the wire on the core.
As a result, the output should be about 5 volts, but if the power is too small, you can take another transformer. After that, check the tension again. If it is not more than 2000 A - the microwkeeping machine is ready to use.