Spot welding Errors and nuances in the assembly of spotter and resistance welding

Today we have spot welding. Consider the errors and nuances in the assembly of spotter and resistance welding.
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This video will be useful for those who want to assemble spot welding - Spot Welder. And also for those who for some reason do not work spot welding.
I want to note that no one has yet given such a volume of information in one video on the subject of resistance welding.
First, I’ll tell you which transformers are suitable and which are better not to take.
I will show how to calculate the power of the transformer magnetic circuit before rewinding.
We will learn to determine the secondary and primary windings and check the windings for proper operation.
Do-it-yourself rewinding of the transformer. We will assemble the electrical part of a powerful contact welding, as well as conduct tests and take measurements of voltage and current strength. And in conclusion, we list the errors and nuances in the assembly of spotter and resistance welding.
What would you like? DIY spotter or spot welding - Spot Welder? The minimum voltage of the spotter should be 6 volts and the current strength from 1000 A. Modular electronics for spot welding has arrived, soon there will be a new video on assembling a budget spotter from such an armored transformer with your own hands.
He alone must give the same current strength as three transformers from microwaves. Most recently, I have assembled with my own hands a fairly powerful contact welding from exactly the same armored transformer. It turned out to be a very cool homemade product.
And so, spot welding. Transformers are armored, rod and toroidal. But,
More stringent performance can be achieved with armored or toroidal transformers. The first thing you should look at when choosing a trance is its size and weight. My transformer for resistance welding is 1 kilowatt and weighs 14.5 kilograms. Transformers from microwave ovens weigh a little more than four kilograms ... If the transformer does not have any information, the overall power can be calculated using a small program. If in doubt and are afraid that the transformer will burn, you can connect it through a light bulb. With the correct connection of a small transformer, the bulb barely burns - if there was a short circuit, the bulb would burn brightly. Transformers from microwave ovens must be connected to the network carefully. Because the secondary winding of a trance from a microwave has more than a thousand volts and this is life threatening.
Now let's start rewinding. The secondary winding is always wound on top of the primary, carefully unwind it. If instead of a cable do it yourself, wrap 5 cores of a copper busbar measuring 7x4 mm in total, which in total can pass a maximum current of 585 A. then this will be almost 150 amperes more than that of the cable. The copper bar is almost a third more efficient. Do not forget that we wind the secondary winding in the same direction in which the native was wound and try not to damage the insulation. Modular electronics are powered by AC voltage. Any small transformer for 9-12 Volts without any rectifiers is suitable - this is important. Automation has no manual mode. But it can be done by soldering a wire to the cathode of the optocoupler and adding a two-channel toggle switch to the circuit to switch modes.
Automation is controlled by the pedal on the pedal.
The big pedal reliably compresses the workpieces, the small one turns on the automation and spot welding cooks. Inside is the usual mikrik and spring. Now we list the errors and nuances in the assembly of spotter and resistance welding
Errors and nuances are as follows. When assembling spot welding, losses must be considered. First of all, this applies to those who want to collect spotter. If your trance produces up to 6 thousand amperes at a voltage of 6 volts, then the cable of mass and the return hammer can be made 2.5 meters long with a cross section of 120 squares. In more detail, I listed the Errors and nuances in the assembly of the spotter and resistance welding in the video. Automation is not a luxury, but a necessity - especially when working with thin metals.
Spot welding will be another video. Where there will be a new cool homemade. I will show a budget spotter. I hope that by that time, measuring clamps will come - I would like to know the maximum current strength.
Resistance welding turned out better than I expected. I like her. This is a really cool DIY make-up.
That's all dear friends. For you, the author of the channel 1000 DIY's and Advice tried - 1000 DIY AND TIPS