Excellent! I've waited 4 long years. ;) Couldn't have done it better myself. (literally.. I could not have). I haven't made the addition yet; have been on the fence: $10 for a pulser or $4000 for a new welder that can already do it. I know, tough call.
Thanks for the comment TOT. I think you have the TIG skill to justify the $4k niceness. I, sadly, do not. I picked up the AHP AlphaTIG late last year and it has exceeded my meager needs. Yellow always gets the blue vs red crowd riled up.
If you have post flow you can have pre-flow. Just hack out a peace of scrap and ground it close to where you are welding. You can go old-scool and use a manual vaulve torch, and just hook op the torch directly to the flow meter if you are made of fittings and gas hoses :D
Yellow, huh! I’ve got an ESAB EMP 215. That’s yellow too. I’m sure that gets them riled up too. Sigh, thinking of replacing it with the new EMP 205 when it comes out later this year.
Here in Brazil a tig soldering machine costs an absurd of expensive !! Almost anyone who needs can afford one. It will help a lot to the whole country (Brazil)! I'll try to make one, very grateful for your teaching!
A real simple, down and dirty way of doing the pulsations. Such a straight mathematical deduction makes all kinds of things happen for the better of us all. I will take a regular smaw (100 percent duty cycle, as that is the gold standard to start with as all is judged by the benchmark.) that I have kicking around and make all the electronics from scratch. Just hope that I still have time to make it happen this year. You all know how life can get in the way for sure.
Thanks for sharing this! Your videography skills are amazing...your explanations clear and concise...wish I'd had more teachers like you back when I was...well lets just say "back in da day" (I'm 67 now and pretty much struggle with everything)😉. Keep up the good work and a shout out to T.O. Tony (btw: I subscribe to him as well)🙏
I have recently found his videos, as weld. ; ) and I’ve been pondering the same “time traveler” theory, regarding Mr Tony, but don’t sell yourself short my good man, I was quite intrigued throughout your modification video as well. Inspiring content from both of you, to which, I’ll have you know I lit my 1st tungsten last night! Thank you guys and keep it up, regardless of when, where, or what, the space time continuum may have you believe.
This video is just what I was looking for... I just bought an older Miller Dialarc HF and want to add the pulse feature to it... I do have a background in embedded controllers, SCADA and PLC Logic and was familiar with terminology you used... The presentation and editing were great... I pick up the machine Saturday and will be ordering these parts as soon as I finish commenting 🤣 Thanks for taking the time to make an awesome video for the Geek community...
Very cool video. I wonder if you'd be interesting in making a project that adds high frequency arc stabilization to a welder. It would be amazing to add not only pulsing, but high frequency, as well.
I was going to build a pulser for my everlast 185 welder but eventually just upgraded to a higher capacity everlast with built-in pulsing. I like the way you implemented yours.
Whoa, you went overboard with IC, but you did it for cheap... I can't really you for that one! I was thinking about BJT, 555, caps, diodes, inductors, and more cost for going with more analog. I've spent too much time learning the stuff that they really don't teach anymore and became hell bent on building a pair of guitar effects pedals made entirely of BJTs.
This is great. My everlast tig welder has pulse but my friend's doesn't. I was going to whip up a circuit for him based a lot on what you show here but you've already done all of the work.
Hi everyone. I bit-banged out some code. This seems to be working for me. Note, I changed the scale values for my own purposes. I am running this on my Syncrowave 250. My welder is using ~9 volts. So I was able to use the multiplexer listed in his video. I tied my grounds together and only ran the TIG Vref though the multiplexer used a separate 5V power supply to power the Arduino. Never allow more than 5V into the Arduino. Here's the sketch I am using: //vars int PWM_DutyCycle = 0; int PWM_DutyCycle_Pin = A0; int PWM_Period = 512; //period in ms int PWM_Period_Pin = A1; //Scale the time of the period or duty by N*1024 milliseconds. //e.g. PWM_PeriodScale=5 will allow a maximum PWM period of 5120 ms or ~0.195Hz int PWM_PeriodScale = 3.5; int PWM_DutyScale = 3.5; int PWM_Out_Pin = 9; //31250 base freq. (Timer1) unsigned long HighTime=1; unsigned long LowTime=0; //Setup PWM Output void setup() { pinMode (PWM_Out_Pin, OUTPUT); pinMode (PWM_DutyCycle_Pin, INPUT); pinMode (PWM_Period_Pin, INPUT); } void loop() { PWM_DutyCycle= analogRead(PWM_DutyCycle_Pin); HighTime = PWM_DutyCycle*PWM_DutyScale; LowTime = PWM_Period*PWM_PeriodScale; //turn on the out pin digitalWrite(PWM_Out_Pin,HIGH); delay(HighTime); //turn pin off digitalWrite(PWM_Out_Pin,LOW); delay(LowTime); }
Pulsing allows deep penetration and low avg heating, generally clever. My takeaway of your crkt was tying the low current pot to the high current pot output. I thought that was brilliant. Not that it was complex but that you came up with that technique. My hat is off to you for that trick. Thx for sharing with the rest of us.
So the design is very simple. With arduino and two potentiometers you create a square signal with high-time and low-time (it could be frequency and duty cycle, doesn't matter). The potentiometer in foot pedal sets high level when the fourth potentiometer sets low level (as % of high level). Now the stuff I didn't know 74 multiplexer can do is brilliant. It takes as input the square signal from arduino and high and low levels from potnetiometers. The square wave drives the output switching it between high and low. And that's it. Brilliant.
Very interesting. However the lead in with the sparking id a red herring. The sparks are from lack of weld purging. On a related site, the miller pulse options are found to be just switches, pots, and ribbon on a pcb as all the logic is already in the main pcb. For that, miller charges over $500., and some of them are obsolete.
Ok not an electronics genius like yourself but I dabble and I never knew you could get blank circuit boards to solder in circuits how ever you liked. I've seen pre built and bread board before but never true blanks. I have bought like six or seven CDI boxes for motorcycles when I could've very easily built each one.
Yes, you should be able to do that using the amperage potentiometer on the front panel. You'll want to measure the voltage across that potentiometer to see if it is compatible with a microcontroller (or whatever circuit you choose to use). If it is 3.3-5v you can use it to power a low-current microcontroller directly. If it is higher you'll need to use a voltage regulator or external power source to power your microcontroller and an op amp to swing the microcontroller output to the range the welder is expecting. I would suggest that running the amperage adjustment potentiometer out into a pedal might be much more useful though. I can't imagine doing any kind of dynamic TIG welding without foot control. What is the make/model of your welder?
Thanks for the reply. It is an Andeli tig 200g. The specs are on this web page and there is a PDF available to download if you are interested. www.andeligroup.com/Inverter-DC-TIG%7CMMA-Welding-Machine-(IGBT-Type)-id866.html. Not the best welder out there but I would like to see if I could mod it. Looks like I am going to have to get a new multimeter.
I was searching this add-on pulser for long since I bought a very light weight Chinese Arc Welder a week ago which doesn't have pulse function. For a pulsed arc welder it could cost much more money. I will try your arduino pulser on my Chinese arc welder first. If it works good, I will try it on my old Miller power source. If it explode! XD Then my welder game is over!
was thinking to do this sort of conversion with a simple timer relai , since my lorch it 252 has already a built in knob (and switch @ torch )for half "ish" amp selection , and this is just a great upgrade for alu and stainless welding , ( now heading for shed )
the sparks are from things not being cleaned propurly like clean your filler rod, tungsten, and what your welding and also dont forget to on the shielding gas
i had similar problems with sparks. hat happend at my shop was a inlet, an air inlet in the gasline. what also can be is a to high argon flow or a unharmonic gasflow there are gasflow reducers cost around 50$. also what can happen is a air flow troutgh the shop when my main door was open it caused a argon flow disturbance close the door problem gone. hope you can fix it in any of this ways. go check the complete gasline and the rest. good job with the pulser ! =)
wow wath a nice video ,it is very instructive and well detailed on how to make a cheap pulser for tig welding. Il be searching for your other videos , thanks a lot.
Very good and still relevant,pass your gray matter over this... How about pwm pulse and oscillation circuit for square wave ac welding for non ferrous welding .Is there a way to do it with out reversing big current values after inverting ,requiring expensive ,noisy contactors ?
I see that this is an older video but my question is, as you seem very knowledgeable about welders, can a pedal be added to a welder that comes with only the on or off feature? If possible that would be interesting. Thanks for the video.
Nice Job! Luckily i own a welder with all needed pulse-settings, but i really like to see problems solved your way... Maybe i can trigger you for a next project (: I've seen this really nice "tig button" on youtube to control amperage by more or less pressing the trigger. I've messed around with an arduino and a fsr, but i'm not happy with the results right now, because it is way too sensitiv ... maybe you have some great idea to solve this? I'd like to purchase the original, but it is way over my budget, particulary because i'm in europe, so there would be shipping and taxes on top ...
Thank you for this now I just have to figure out what I have that I could trade to my buddy that is into Electronics to make me one he comes over and lusts at some of my junk so I just have to find the one thing I'm willing to part with I don't take that much but I've always wanted a pulse but I'm not willing to buy a new welder and this will be really nice thank you again nice work nice video I could probably do it myself but that's what buddies are for I mean hell Tony suckered you into it and I just have to figure out how to do the same to my friend😎
Your spark probleme is due to the calamine in that kind of metal(angle and flat bar)try with square tubing im sure the result is much better.If you want to tig welding flat bar or angle you need to grind it to éleminate the calamine on the surface
You should had put circuit decouplers like optocouplers in-between welder circuits and Arduino outputs it is to avoid damaging your diy board if something goes wrong
have you seen these new "cold welding" tig videos? they spot eld with tig and without filler and protection mask. somehow they use a new technique of controlling the tig...
You're my new hero. What was the major issue with using a self contained off the shelf PWM controller? You couldn't get the frequency slow enough? I totally applaud the effort, I'm going to have to watch the video a few times and do some more homework to fully grasp what you've done! Did you ever get around to posting the source code?
I'm about to buy my first welding machine and your design may save me quite a bunch of money. Does the welding machine need to be "pedal-ready"? I see machines with only a two-pin connector for the torch switch, and other machines with five-pin (I think) connectors. Is this design suitable for the two-pin connectors? Most of the five-pin connector machines can already pulse the arc for what I've found.
I like the project, and it's just what I need too without buying a new welder. But Mine is a Lincoln (out of warranty) with a 24 volt reference voltage. What do I do with that??
Very cool. I'm trying to turn a DC MIG into an high frequency square wave TIG in similar fashion. I need high current components though. Any suggestions? I was thinking of a mechanical points device.
Fantastic video, thank you so much for this exciting combination of welding and arduino. Is it possible to use a mosfet like IRLZ44 to do the multiplexing just by changing the analogWrite value? What is the reason for using the multiplexer?
that's pretty sick! But your welding shouldn't be sparking like that at all! Either your material is contaminated , or your gas flow is too little, OR too much! If it's too much flow, it will cause turbulence which will draw oxygen into your molten metal! The goal of 100% argon gas is what suppose to protect the hot metal from oxygen. Run roughly 15-20 CFH!
What is the 5 pin connector called? It almost looks like a 5 pin DIN (240 degree) but it's not. I also looked at GX connectors which appear to match the circular pattern but it's 15mm in diameter vs 16mm for the GX. Thanks
Can I add a pulser to my DC inverter tig? And can I add a amp controlled pedal. I swapped my thumb switch for a foot pedal, but it only turns off and on at a fixed amperage. I do have a dial for amps. From 10-200 amps.
hahaha the end code was missing. read pots was never defined. Thankfully it wasn't to hard too finish. Also not understanding the simple mode. seems like it shouldn't be in there. Soldered up a little board and it works nice
Nothing special in the readPots() function. Arduino analog input the pots values are bouncing and not make accurates values. I think he store the potenziomenter values in a array and then he check if the old values are the same. Sorry for my english . Greetings from Italy
Great video, I would love to build one to use on my chinese ac/dc tig which doesn't have a pulse function but sadly the output for the foot controller is `15v - any thoughts of a pulser that could work on machines other than volt?
@This Stuff I Do. Can we talk about doing a mod like this on my Miller 252 mig welder? I need to add pulse to it if possible. It doesn’t use a tig pedal obviously cause it’s a mig welder. But... I do use a xr alumapro push pull gun to do all my aluminum welding with this machine which has the adjustment knob on it so I would think that circuit would work. I am not the best with electronics and I have zero coding skills.
Scope traces are the only thing more/less satisfying that final application install. Point being that one has yet to subject $$$ equipment to one’s “proven” design.
I have a Lincoln Tig 275 Square Wave without pulse. I would like one built for my machine. I would like it to be able to change the pulse rate by a knob or Digital display. I can get you the schematics of the Lincoln Tig 275
Could you email me the lay out solider point and what wires to hook up to the tig pedal. My welder is a scratch start with out foot pedal I've added a 7 pin plug to the machine to add foot pedal already. I'm in the works of adding high frequency arc start and stabilizer to the machine. All help would be great. Thanks for the video and keep up the good work.
Nice. I got a DC pulse, but wouldn't mind an AC pulse as well. Don't hink I'd risk breaking my welder, but this is a kickass idea. Don't even have a pedal, but you could probebly intigrate this setup with a button as well... When is this avalable on ebay? :)
Is there any way this video can be redone for dummies? I ordered all the parts, soldered them onto a board and realized there is still more to do. I have no idea how to program the chip with the code. I understand I know nothing about Arduino so no need to bag on me for it. Best case would be if someone popped in here and offered to pick up where I'm stuck....I'm not asking for a freebie
I went to build this but using the Arduino 1.8.9 program I get an error message when it gets to the line "ReadPots();" which just says "ReadPots" was not declared in this scope. What's that mean? I'm not a very seasoned coder so I'm a little lost with that. Should I just go ahead and load the program or does someone know what it needs for that line to satisfy the verify check?
@@devilvortex1 here it is again: //vars int PWM_DutyCycle = 0; int PWM_DutyCycle_Pin = A0; int PWM_Period = 512; //period in ms int PWM_Period_Pin = A1; //Scale the time of the period or duty by N*1024 milliseconds. //e.g. PWM_PeriodScale=5 will allow a maximum PWM period of 5120 ms or ~0.195Hz int PWM_PeriodScale = 3.5; int PWM_DutyScale = 3.5; int PWM_Out_Pin = 9; //31250 base freq. (Timer1) unsigned long HighTime=1; unsigned long LowTime=0; //Setup PWM Output void setup() { pinMode (PWM_Out_Pin, OUTPUT); pinMode (PWM_DutyCycle_Pin, INPUT); pinMode (PWM_Period_Pin, INPUT); } void loop() { PWM_DutyCycle= analogRead(PWM_DutyCycle_Pin); HighTime = PWM_DutyCycle*PWM_DutyScale; LowTime = PWM_Period*PWM_PeriodScale;
//turn on the out pin digitalWrite(PWM_Out_Pin,HIGH); delay(HighTime); //turn pin off digitalWrite(PWM_Out_Pin,LOW); delay(LowTime); }
i just got lucky and picked up an excellent deal on a brand new import 200 amp ac/dc tig/mma with pulse and high freq.. lol, sorry, guess im gonna have to be counted out.
This was an awesome video. Besides solving a huge problem on a welder, the production of the video was great too! I was wondering if you take jobs? If I could send you my welder and you could do some stuff? Great Video!
I know you wanted to make easy for people without embedded background.. but you know you can program arduino with C.. Also could have been done with 555 ics..
do you have a schematic for using 2 Channel PWM Pulse Frequency Adjustable Duty Cycle Square Wave Rectangular Wave Signal Generator Module Frequency Range: 1Hz~150KHz model XY-PWM
Did you ever get around to posting the audrino code? i have all the parts sitting infront of me right now ready. im trying to gleam what info i can by pausing over the bitbang section, but im new to that kind of coding. copy and paste document would help so much and help alieviate any worries of me messing that part up. thanks, Cody. p.s. email is Mackn918@gmail.com
Would like to know how this is all made in diagram form. Its a bit much to ask but if you can make a diagram of how this is put together it be much easier to follow the video. I am trying to use a WHDTS Adjustable Signal Generator to replicate what you have done to simplify but I am having brain fart so smelly its confusing me lol.
I recently fixed up my code and added an LCD screen to my setup based on this. I have to document my ladders for future use as well as some one lines. I can post them here along with my updated code.
@@jzurek112 can you post your code and schematics? Ok r email them to me please @ mackn918@gmail.com I built this board 2 years ago and still haven't got it to work as I don't know how to write custom Arduino code. Thanks.
Excellent! I've waited 4 long years. ;) Couldn't have done it better myself. (literally.. I could not have). I haven't made the addition yet; have been on the fence: $10 for a pulser or $4000 for a new welder that can already do it. I know, tough call.
Thanks for the comment TOT. I think you have the TIG skill to justify the $4k niceness. I, sadly, do not. I picked up the AHP AlphaTIG late last year and it has exceeded my meager needs. Yellow always gets the blue vs red crowd riled up.
If you have post flow you can have pre-flow. Just hack out a peace of scrap and ground it close to where you are welding. You can go old-scool and use a manual vaulve torch, and just hook op the torch directly to the flow meter if you are made of fittings and gas hoses :D
Yellow, huh! I’ve got an ESAB EMP 215. That’s yellow too. I’m sure that gets them riled up too. Sigh, thinking of replacing it with the new EMP 205 when it comes out later this year.
4k for the Stel..ehm htp? Looks a bit pricey🤔, i thought It was cheaper tbh😅
@@thisstuffido9141 sis you ever upload the full code as the code you show dont work, thanks
Here in Brazil a tig soldering machine costs an absurd of expensive !! Almost anyone who needs can afford one. It will help a lot to the whole country (Brazil)! I'll try to make one, very grateful for your teaching!
A real simple, down and dirty way of doing the pulsations. Such a straight mathematical deduction makes all kinds of things happen for the better of us all.
I will take a regular smaw (100 percent duty cycle, as that is the gold standard to start with as all is judged by the benchmark.) that I have kicking around and make all the electronics from scratch. Just hope that I still have time to make it happen this year. You all know how life can get in the way for sure.
Thanks for sharing this! Your videography skills are amazing...your explanations clear and concise...wish I'd had more teachers like you back when I was...well lets just say "back in da day" (I'm 67 now and pretty much struggle with everything)😉. Keep up the good work and a shout out to T.O. Tony (btw: I subscribe to him as well)🙏
I have recently found his videos, as weld. ; ) and I’ve been pondering the same “time traveler” theory, regarding Mr Tony, but don’t sell yourself short my good man, I was quite intrigued throughout your modification video as well. Inspiring content from both of you, to which, I’ll have you know I lit my 1st tungsten last night! Thank you guys and keep it up, regardless of when, where, or what, the space time continuum may have you believe.
This video is just what I was looking for... I just bought an older Miller Dialarc HF and want to add the pulse feature to it... I do have a background in embedded controllers, SCADA and PLC Logic and was familiar with terminology you used...
The presentation and editing were great...
I pick up the machine Saturday and will be ordering these parts as soon as I finish commenting 🤣
Thanks for taking the time to make an awesome video for the Geek community...
Very cool video. I wonder if you'd be interesting in making a project that adds high frequency arc stabilization to a welder. It would be amazing to add not only pulsing, but high frequency, as well.
Get an Arc Pig.
I was going to build a pulser for my everlast 185 welder but eventually just upgraded to a higher capacity everlast with built-in pulsing. I like the way you implemented yours.
Whoa, you went overboard with IC, but you did it for cheap... I can't really you for that one!
I was thinking about BJT, 555, caps, diodes, inductors, and more cost for going with more analog.
I've spent too much time learning the stuff that they really don't teach anymore and became hell bent on building a pair of guitar effects pedals made entirely of BJTs.
This is great. My everlast tig welder has pulse but my friend's doesn't. I was going to whip up a circuit for him based a lot on what you show here but you've already done all of the work.
Hi everyone. I bit-banged out some code. This seems to be working for me. Note, I changed the scale values for my own purposes. I am running this on my Syncrowave 250. My welder is using ~9 volts. So I was able to use the multiplexer listed in his video. I tied my grounds together and only ran the TIG Vref though the multiplexer used a separate 5V power supply to power the Arduino. Never allow more than 5V into the Arduino. Here's the sketch I am using:
//vars
int PWM_DutyCycle = 0;
int PWM_DutyCycle_Pin = A0;
int PWM_Period = 512; //period in ms
int PWM_Period_Pin = A1;
//Scale the time of the period or duty by N*1024 milliseconds.
//e.g. PWM_PeriodScale=5 will allow a maximum PWM period of 5120 ms or ~0.195Hz
int PWM_PeriodScale = 3.5;
int PWM_DutyScale = 3.5;
int PWM_Out_Pin = 9; //31250 base freq. (Timer1)
unsigned long HighTime=1;
unsigned long LowTime=0;
//Setup PWM Output
void setup() {
pinMode (PWM_Out_Pin, OUTPUT);
pinMode (PWM_DutyCycle_Pin, INPUT);
pinMode (PWM_Period_Pin, INPUT);
}
void loop()
{
PWM_DutyCycle= analogRead(PWM_DutyCycle_Pin);
HighTime = PWM_DutyCycle*PWM_DutyScale;
LowTime = PWM_Period*PWM_PeriodScale;
//turn on the out pin
digitalWrite(PWM_Out_Pin,HIGH);
delay(HighTime);
//turn pin off
digitalWrite(PWM_Out_Pin,LOW);
delay(LowTime);
}
Does this work with his schematics? Thanks you I appreciate it.
@@codymack6343it should work fine.
Do I need to add "PWM_Period= analogRead(PWM_Period_Pin);" ?
with his code can I set pulse freq Hz ?
@@novel819 this code allows you to manually set the pulse. So you play with the dials until you find up time and down time plus down time percentage.
Pulsing allows deep penetration and low avg heating, generally clever. My takeaway of your crkt was tying the low current pot to the high current pot output. I thought that was brilliant. Not that it was complex but that you came up with that technique. My hat is off to you for that trick. Thx for sharing with the rest of us.
Thank you for this video. Im gonna add pulse to my stickwelder... I just checked, its 5V control circuit as well!
So the design is very simple. With arduino and two potentiometers you create a square signal with high-time and low-time (it could be frequency and duty cycle, doesn't matter). The potentiometer in foot pedal sets high level when the fourth potentiometer sets low level (as % of high level). Now the stuff I didn't know 74 multiplexer can do is brilliant. It takes as input the square signal from arduino and high and low levels from potnetiometers. The square wave drives the output switching it between high and low. And that's it. Brilliant.
Very interesting. However the lead in with the sparking id a red herring. The sparks are from lack of weld purging.
On a related site, the miller pulse options are found to be just switches, pots, and ribbon on a pcb as all the logic is already in the main pcb. For that, miller charges over $500., and some of them are obsolete.
I'm inspired! Going out to my workshop to pull my old TIG machine apart and measure some voltages,,,
Ok not an electronics genius like yourself but I dabble and I never knew you could get blank circuit boards to solder in circuits how ever you liked. I've seen pre built and bread board before but never true blanks. I have bought like six or seven CDI boxes for motorcycles when I could've very easily built each one.
The electronics went by pretty quickly. Perhaps I'll watch it again..sure as hell a great fix..
I saw your comment on ToT's video, it's really well made! You've got yourself a subscriber
me too!
Yes, you should be able to do that using the amperage potentiometer on the front panel. You'll want to measure the voltage across that potentiometer to see if it is compatible with a microcontroller (or whatever circuit you choose to use). If it is 3.3-5v you can use it to power a low-current microcontroller directly. If it is higher you'll need to use a voltage regulator or external power source to power your microcontroller and an op amp to swing the microcontroller output to the range the welder is expecting.
I would suggest that running the amperage adjustment potentiometer out into a pedal might be much more useful though. I can't imagine doing any kind of dynamic TIG welding without foot control.
What is the make/model of your welder?
Thanks for the reply. It is an Andeli tig 200g. The specs are on this web page and there is a PDF available to download if you are interested. www.andeligroup.com/Inverter-DC-TIG%7CMMA-Welding-Machine-(IGBT-Type)-id866.html. Not the best welder out there but I would like to see if I could mod it. Looks like I am going to have to get a new multimeter.
Pretty cool. I was thinking of doing one myself, but like you, I haven’t done much electronic design for a while.
Wow i cant believe more people haven't seen this!! Next frequency adjustment from ac arc to dc back to ac ^^
I was searching this add-on pulser for long since I bought a very light weight Chinese Arc Welder a week ago which doesn't have pulse function. For a pulsed arc welder it could cost much more money. I will try your arduino pulser on my Chinese arc welder first. If it works good, I will try it on my old Miller power source. If it explode! XD Then my welder game is over!
was thinking to do this sort of conversion with a simple timer relai , since my lorch it 252 has already a built in knob (and switch @ torch )for half "ish" amp selection , and this is just a great upgrade for alu and stainless welding , ( now heading for shed )
I was going to build something like this many years back. I ended up buying a nice everlast welder before I could ever build it.
the sparks are from things not being cleaned propurly like clean your filler rod, tungsten, and what your welding and also dont forget to on the shielding gas
This looks like an interesting circuit to make. Too bad I already have an Everlast welder with a pulser built in.
i had similar problems with sparks. hat happend at my shop was a inlet, an air inlet in the gasline. what also can be is a to high argon flow or a unharmonic gasflow there are gasflow reducers cost around 50$. also what can happen is a air flow troutgh the shop when my main door was open it caused a argon flow disturbance close the door problem gone. hope you can fix it in any of this ways. go check the complete gasline and the rest. good job with the pulser ! =)
Or a contaminated fill of Argon. Try a different bottle.
I assume circuit could be used for chopping and alternating for square wave ac if I knew how to arrange it ?
Schematic & code please?
wow wath a nice video ,it is very instructive and well detailed on how to make a cheap pulser for tig welding. Il be searching for your other videos , thanks a lot.
Great to see your way of working stuff out
You should upgrade It as low and high current setting function that will be perfect.
Very good and still relevant,pass your gray matter over this... How about pwm pulse and oscillation circuit for square wave ac welding for non ferrous welding .Is there a way to do it with out reversing big current values after inverting ,requiring expensive ,noisy contactors ?
mill scale is what is causing your sparklers......grind off before welding.....cheers
Very nice job
I’d like to modified mine. Do you have any suggestions forum or other ways where your project is explained for dummies 😀
I see that this is an older video but my question is, as you seem very knowledgeable about welders, can a pedal be added to a welder that comes with only the on or off feature? If possible that would be interesting. Thanks for the video.
In his video the one pot is emulating the resistor in the foot pedle
Nice Job! Luckily i own a welder with all needed pulse-settings, but i really like to see problems solved your way...
Maybe i can trigger you for a next project (:
I've seen this really nice "tig button" on youtube to control amperage by more or less pressing the trigger. I've messed around with an arduino and a fsr, but i'm not happy with the results right now, because it is way too sensitiv ... maybe you have some great idea to solve this? I'd like to purchase the original, but it is way over my budget, particulary because i'm in europe, so there would be shipping and taxes on top ...
What is the principle? Why does changing background time affect result? I need to study Tig principles.
Thank you for this now I just have to figure out what I have that I could trade to my buddy that is into Electronics to make me one he comes over and lusts at some of my junk so I just have to find the one thing I'm willing to part with
I don't take that much but I've always wanted a pulse but I'm not willing to buy a new welder and this will be really nice thank you again nice work nice video I could probably do it myself but that's what buddies are for
I mean hell Tony suckered you into it and I just have to figure out how to do the same to my friend😎
Awesome I just wish I understood more of it. How can I better educate myself on this
Your spark probleme is due to the calamine in that kind of metal(angle and flat bar)try with square tubing im sure the result is much better.If you want to tig welding flat bar or angle you need to grind it to éleminate the calamine on the surface
Really gets to me when a UTube provider assumes everyone is a programmer/engineer, not providing any usable information.
You should had put circuit decouplers like optocouplers in-between welder circuits and Arduino outputs it is to avoid damaging your diy board if something goes wrong
have you seen these new "cold welding" tig videos? they spot eld with tig and without filler and protection mask.
somehow they use a new technique of controlling the tig...
Nice vid man, thanks:) Can something like this be done on a Chicago electric tig & stick machine?
good day. excellent video could you put the connection diagram to the plant because my plant only has two cables please
Great video! You’re good at this!!! Subscribed.
You're my new hero. What was the major issue with using a self contained off the shelf PWM controller? You couldn't get the frequency slow enough? I totally applaud the effort, I'm going to have to watch the video a few times and do some more homework to fully grasp what you've done! Did you ever get around to posting the source code?
I posted the code I used yesterday.
Jeremy Zurek , I can’t find the source code anywhere. Could you share a link please?
@@jzurek112 where? Cannot find it here
I'm about to buy my first welding machine and your design may save me quite a bunch of money. Does the welding machine need to be "pedal-ready"? I see machines with only a two-pin connector for the torch switch, and other machines with five-pin (I think) connectors. Is this design suitable for the two-pin connectors? Most of the five-pin connector machines can already pulse the arc for what I've found.
I like the project, and it's just what I need too without buying a new welder. But Mine is a Lincoln (out of warranty) with a 24 volt reference voltage. What do I do with that??
Very cool. I'm trying to turn a DC MIG into an high frequency square wave TIG in similar fashion. I need high current components though. Any suggestions? I was thinking of a mechanical points device.
Fantastic video, thank you so much for this exciting combination of welding and arduino. Is it possible to use a mosfet like IRLZ44 to do the multiplexing just by changing the analogWrite value? What is the reason for using the multiplexer?
can i get a parts list for this build i want do add a pedal to my old stick welder so i can TIG and weld aluminum too
Is there any reason this couldn't be applied to the trigger on a MIG? Could be used to turn a cheaper DC mig into a pulse mig (which are dear).
that's pretty sick! But your welding shouldn't be sparking like that at all! Either your material is contaminated , or your gas flow is too little, OR too much! If it's too much flow, it will cause turbulence which will draw oxygen into your molten metal! The goal of 100% argon gas is what suppose to protect the hot metal from oxygen. Run roughly 15-20 CFH!
gas lens
What is the 5 pin connector called? It almost looks like a 5 pin DIN (240 degree) but it's not. I also looked at GX connectors which appear to match the circular pattern but it's 15mm in diameter vs 16mm for the GX. Thanks
Can I add a pulser to my DC inverter tig? And can I add a amp controlled pedal. I swapped my thumb switch for a foot pedal, but it only turns off and on at a fixed amperage. I do have a dial for amps. From 10-200 amps.
any chance you have the Arduino code available to grab a copy of it ??
hahaha the end code was missing. read pots was never defined. Thankfully it wasn't to hard too finish. Also not understanding the simple mode. seems like it shouldn't be in there. Soldered up a little board and it works nice
any chance you could post the remaining lines of code for us beginners?
@@penztoy see my reply 11 months ago. It'll work with his schematic and get you going.
Nothing special in the readPots() function. Arduino analog input the pots values are bouncing and not make accurates values. I think he store the potenziomenter values in a array and then he check if the old values are the same. Sorry for my english . Greetings from Italy
Great video, I would love to build one to use on my chinese ac/dc tig which doesn't have a pulse function but sadly the output for the foot controller is `15v - any thoughts of a pulser that could work on machines other than volt?
@This Stuff I Do. Can we talk about doing a mod like this on my Miller 252 mig welder? I need to add pulse to it if possible. It doesn’t use a tig pedal obviously cause it’s a mig welder. But... I do use a xr alumapro push pull gun to do all my aluminum welding with this machine which has the adjustment knob on it so I would think that circuit would work. I am not the best with electronics and I have zero coding skills.
Great vid! Thanks for sharing!
Scope traces are the only thing more/less satisfying that final application install. Point being that one has yet to subject $$$ equipment to one’s “proven” design.
Nice job, do you have a schematic available for download?
I have a Lincoln Tig 275 Square Wave without pulse. I would like one built for my machine. I would like it to be able to change the pulse rate by a knob or Digital display. I can get you the schematics of the Lincoln Tig 275
Could you email me the lay out solider point and what wires to hook up to the tig pedal. My welder is a scratch start with out foot pedal I've added a 7 pin plug to the machine to add foot pedal already. I'm in the works of adding high frequency arc start and stabilizer to the machine. All help would be great. Thanks for the video and keep up the good work.
Is the pulser still going strong? Pls answer, im just collecting the material as we speak.
I'd also like the schematics for this
Nice. I got a DC pulse, but wouldn't mind an AC pulse as well. Don't hink I'd risk breaking my welder, but this is a kickass idea. Don't even have a pedal, but you could probebly intigrate this setup with a button as well... When is this avalable on ebay? :)
Is there any way this video can be redone for dummies? I ordered all the parts, soldered them onto a board and realized there is still more to do. I have no idea how to program the chip with the code. I understand I know nothing about Arduino so no need to bag on me for it. Best case would be if someone popped in here and offered to pick up where I'm stuck....I'm not asking for a freebie
Any chance of getting a schematic or the Arduino code?
Hi i have a ac dc tig machine 220 amp to be get one of these modules to pulse what it cost get one ready maid and ship to me in South Africa
I went to build this but using the Arduino 1.8.9 program I get an error message when it gets to the line "ReadPots();" which just says "ReadPots" was not declared in this scope. What's that mean? I'm not a very seasoned coder so I'm a little lost with that. Should I just go ahead and load the program or does someone know what it needs for that line to satisfy the verify check?
Try using my code posted above about 11 months ago.
@@jzurek112 link? Cant find it.
@@devilvortex1 look through all the comments. My code is below.
@@devilvortex1 here it is again:
//vars
int PWM_DutyCycle = 0;
int PWM_DutyCycle_Pin = A0;
int PWM_Period = 512; //period in ms
int PWM_Period_Pin = A1;
//Scale the time of the period or duty by N*1024 milliseconds.
//e.g. PWM_PeriodScale=5 will allow a maximum PWM period of 5120 ms or ~0.195Hz
int PWM_PeriodScale = 3.5;
int PWM_DutyScale = 3.5;
int PWM_Out_Pin = 9; //31250 base freq. (Timer1)
unsigned long HighTime=1;
unsigned long LowTime=0;
//Setup PWM Output
void setup() {
pinMode (PWM_Out_Pin, OUTPUT);
pinMode (PWM_DutyCycle_Pin, INPUT);
pinMode (PWM_Period_Pin, INPUT);
}
void loop()
{
PWM_DutyCycle= analogRead(PWM_DutyCycle_Pin);
HighTime = PWM_DutyCycle*PWM_DutyScale;
LowTime = PWM_Period*PWM_PeriodScale;
//turn on the out pin
digitalWrite(PWM_Out_Pin,HIGH);
delay(HighTime);
//turn pin off
digitalWrite(PWM_Out_Pin,LOW);
delay(LowTime);
}
Couldn't you use 2 voltage regulators and 2 horn relays for an easy pulsing set up
how can i dp this with a 42 volt input, like on a Lincoln?
You need a dc to dc convert down to 5v look at ebat or aliexpress banggood etc
Hehe, first time i see an Arduino soldered in upside-down. Be careful, all the electrons may fall out!
Would you be willing to build one for a Miller mig machine?
Wouldn't be easier to use 555 for a pulse generator?
Can you post the code, please?
I wonder if Ican do this for esab rebel.
i just got lucky and picked up an excellent deal on a brand new import 200 amp ac/dc tig/mma with pulse and high freq.. lol, sorry, guess im gonna have to be counted out.
Hi guys can anyone in the comments tell me if I can hook this up in place of the current control pot of my welder as I don't have a Foot control port
This was an awesome video. Besides solving a huge problem on a welder, the production of the video was great too! I was wondering if you take jobs? If I could send you my welder and you could do some stuff? Great Video!
I have a basic Miller Diversion. I want one of these but Im too lazy to build one. There must be budding entrepreneurs who build and sell these
Muito bom amigo
I know you wanted to make easy for people without embedded background.. but you know you can program arduino with C.. Also could have been done with 555 ics..
Hi, great job there.... Do You have the Arduino code? I've build the board, but i don't know anything about Arduino coding... Greetings from Argentina
Is there any way you can send me a copy of the code you used on arduino
¡Genial! very understand, thank.
A lack of pulsing capability does not under any circumstances cause sparklers.
do you have a schematic for using 2 Channel PWM Pulse Frequency Adjustable Duty Cycle Square Wave Rectangular Wave Signal Generator Module Frequency Range: 1Hz~150KHz model XY-PWM
Can you share the tutorial?
muy buena la información porfa me podría pasar el código
awesome
" An avid time traveller.." hahaha. Any chance you might be willing to share the source code and schematics?
Sure thing. I'll do a write-up and post when I have a moment.
Count me in please!
Did you ever get around to posting the audrino code? i have all the parts sitting infront of me right now ready. im trying to gleam what info i can by pausing over the bitbang section, but im new to that kind of coding. copy and paste document would help so much and help alieviate any worries of me messing that part up. thanks, Cody. p.s. email is Mackn918@gmail.com
@@thisstuffido9141 I posted the code I'm using yesterday.
@@alexeivaningen I posted the code I am using yesterday.
thank you
Can you build me
One for a miller synchrowave 180
So, I can add a Pulse feature to my Dc tig welder?
Yes
Will that help with welding aluminum
@@Homehous still need ac to weld aluminum.
Instant sub.
Would like to know how this is all made in diagram form. Its a bit much to ask but if you can make a diagram of how this is put together it be much easier to follow the video. I am trying to use a WHDTS Adjustable Signal Generator to replicate what you have done to simplify but I am having brain fart so smelly its confusing me lol.
I recently fixed up my code and added an LCD screen to my setup based on this. I have to document my ladders for future use as well as some one lines. I can post them here along with my updated code.
@@jzurek112 can you post your code and schematics? Ok r email them to me please @ mackn918@gmail.com
I built this board 2 years ago and still haven't got it to work as I don't know how to write custom Arduino code. Thanks.
@@codymack6343 I posted the code about a year ago.