Welding machine from "Change" in "String". We collect DC welding machine to redo the welding inverter in the semiautomatic

Semi-automatic welding - This is a functional device that can be purchased ready or made from. It should be noted that the manufacture of a semi-automatic device from the inverter device is not the task of simple, but if desired it can be solved. Those who put such a goal, it is necessary to study the principle of operation of the semi-automatic themed photos and video prepare all necessary equipment and components.

What will be required for the alteration of the inverter in the semiautomatic

To redo the inverter, making a functional welding semiautomatic from it, you must find the following equipment and additional components:

inverter, capable of forming a welding current by force 150 A;
the mechanism that will be responsible for the supply of welding wire;
the main working element is a burner;
the hose through which the welding wire will be supplied;
hose for supplying protective gas to the welding zone;
the coil with the welding wire (such a coil will need to be subjected to some alterations);
electronic unit, managing the work of your homemade semi-automatic.

Separate attention should be devoted to the alteration of the feeding device, at the expense of which the welding wire is supplied to the welding zone, moving along the flexible hose. In order for the weld of the seam to be obtained by high-quality, reliable and neat, the feed rate of the flexible hose should correspond to the speed of its melting.

Since with welding with the use of semiautoma, wire can be used from different materials and various diameters, its feeding should be adjusted. It is such a function - adjusting the feeding speed of the welding wire - just the feeding mechanism of the semiautoma should be performed.

Internal layout Coil for wire Wire supply mechanism (view 1)
Wire supply mechanism (view 2) Fastening of the welding sleeve to the flow mechanism of the homemade burner

The most common wire diameters used during semi-automatic welding are 0.8; one; 1.2 and 1.6 mm. The wire before performing welding is wound on special coils, which are the prefixes of semi-automatic apparatus, fixed on them with the help of simple structural elements. In the process of performing welding, the wire is automatically supplied, which significantly reduces the time spent on such a technological operation, simplifies it and makes more efficient.

The main element of the electron control unit is a microcontroller, which is responsible for regulation and stabilization of the welding current. It is from this element of the electronic circuit of the welding semiautoma to depend on the parameters of the operating current and the possibility of their regulation.

How to redo the inverter transformer

In order for the inverter to be used for homemade semi-automatic, its transformer must be subjected to some alterations. It is easy to perform such a rework with your own hands, you just need to adhere to certain rules.

In order to bring the characteristics of the inverter transformer in accordance with those that are necessary for the semi-automatic manner, it should be copper with its copper strip, which causes a winding from thermal paper. It should be borne in mind that for these purposes it is impossible to use a conventional thick wire that will be very hot.

The secondary winding of the inverter transformer is also necessary to redo. To do this, do the following: winding a winding consisting of three layers of tin, each of which is necessary to isolate with fluoroplastic tape; The ends of the existing winding and made with their own hands to solder together, which will increase the conductivity of currents.

The structural used for its inclusion in the welding semiautomatic must necessarily provide for the presence of a fan that is necessary for efficiently cooling the device.

Setting inverter used for semi-automatic welding

If you decide to make a welding semi-automatic welding semi-automatic, using the inverter for this, you must pre-de-energize this equipment. So that such a device does not overheat, it is necessary to place its rectifiers (input and output) and power keys on radiators.

In addition, in that part of the inverter housing, where the radiator is located, it is stronger, it is best to mount the thermal sensor, which will be responsible for turning off the machine if it is overheated.

After all of the above procedures are made, you can connect the power part of the device with its control unit and connect it to electrical network. When the network connection indicator lights up, an oscilloscope should be connected to the inverter outputs. Using this device, you need to find electrical pulses with a frequency of 40-50 kHz. The time between the formation of such pulses should be 1.5 μs, which is regulated by changing the voltage value entering the device input.

It is also necessary to check the pulses that reflect on the oscilloscope screen had rectangular shapeAnd their front was no more than 500 ns. If all the parameters verified correspond to the required values, the inverter can be connected to the electrical network. The current coming from the semi-automatic exit must have a force of at least 120 A. if the value of current is less, this may mean that voltage is supplied to the wires, the value of which does not exceed 100 V. In the event of such a situation, it is necessary to do the following: Test equipment By changing the current force (it is necessary to constantly monitor the voltage on the condenser). In addition, the temperature inside the device should be constantly monitored.

After the semi-automatic is tested, it is necessary to check it under load. To make such an inspection, the welding wires are connected to the retail, the resistance of which is at least 0.5 ohms. Such a row must withstand current by force of 60 A. The power of the current, which in such a situation enters the welding burner, is controlled by an ammeter. If the current of the current when using the loading row does not correspond to the required parameters, the resistance value this device Pick up empirically.

How to use a welding inverter

After starting the semi-automatic, which you collected with your own hands, the value of the current of the current should be displayed on the inverter indicator, equal to 120 A. if everything is done correctly, then it will happen. However, the eight of the inverter can be displayed on the inverter. The reason for this is most often insufficient voltage in welding wires. It is better to immediately find the cause of such a malfunction and quickly eliminate it.

If everything is done correctly, the indicator will correctly show the power of the welding current adjustable using special buttons. The operating current adjustment interval, which is provided, is in the range of 20-160 A.

How to control the correctness of the equipment

So that the welding semiautomatic agent you gathered with your own hands served you for a long timebetter to constantly control temperature mode Inverter works. To make such a control, you must press two buttons simultaneously, after which the temperature of the hot radiator itself inverter will be displayed on the indicator. The normal operating temperature is the one that the value of which does not exceed 75 degrees Celsius.

If this value is exceeded, then, in addition to information displayed on the indicator, the inverter will start to make an intermittent beep, which should immediately pay attention to. In this case (as well as during a breakdown or circuit of the thermal sensor) electronic circuit The devices will automatically reduce the operating current to the value of 20a, and the beep will be published until the equipment comes to normal. In addition, the malfunction of the equipment made by its own hands may indicate the error code (ERR), highlighted on the inverter indicator.

If you decide to assemble the welding semiautomatic device with your own hands from the inverter, the scheme and detailed instructions They will become indispensable satellites on the way to achieving the goal. The easiest way is to purchase factory semi-automatic cedar type 160, Kaiser MIG 300 with the required ampere indicator. But many seek to do everything with their own hands. This is not so simple, but if you wish to achieve a positive result, you will be able.

MIG, MAG, MMA Welding requires the use of appropriate devices. MIG Mag is a semi-automatic welding, which is performed in an inert argon gas medium. Sometimes for welding MiG magician use carbon dioxide. MMA welding is called manual arc processing with electrodes, which are applied special coating. If you work with a stainless steel, then MMA welding is carried out only at a constant current.

Since we are talking about how you can collect with your own hands a full-fledged semi-automatic inverter based on the inverter, you are not interested in MMA, and Mig Mag Weld.

To collect homemade apparatusA decent analog for cedar 160, Kaiser Mig 300, with your own hands, you will need a scheme, video instruction and the necessary elements of the semi-automatic design. These include:

Inverter. Determine its welding abilities, choosing the resulting current. Usually the masters collect devices capable of issuing 150 amps, 170 amps or 190 amps. The more ampere, the higher the ability of your welding device;
Mechanism feed. We will tell about it separately;
Burner;
Electrodes supply hose;
Coil with special wire. This prefix is \u200b\u200beasily attached to the design by any way convenient for you;
Control unit your aggregate for welding.

Now, with regard to the feeding mechanism for semi-automatic and some important points.

It is responsible for the supply of electrodes with a flexible hose to the welding point.
The optimal feed rate of the electrode wire corresponds to the speed of its melting during welding works with their own hands.
From the feed rate of the wire depends the quality of the seam obtained with its own hands.
It is recommended to make a semi-automatic with the ability to adjust the speed. This will allow adapting semiautomat under different type used electrodes.
The most sought-after electrode wires have a diameter from 0.8 to 1.6 mm. It needs to be wounded on the coil and charge the inverter.
If you provide a fully automated feed, you do not have to do it with your own hands, and therefore will significantly reduce the time spent on welding activities.
The control unit is equipped with a regulation channel that is responsible for current stabilization.
The behavior of amps, that is, the semi-automatic current, adjusts the special microcontroller. It performs its work in the latitude and pulse mode of operation. From its filling directly depends the voltage created in the condenser. This affects the parameters of the welding current.

Preparation of semi-automatic transformer

In order to make the semi-automatic man made, it worked no worse than welding machine Type cedar 160, Kaiser MIG 300, it is necessary to deal with the features of the preparation of the transformer.

Wrap it with a copper strip. Its width should be 4 cm, and the thickness is 30;
Before this, the strip is wrapped with thermal paper. Suitable material used in cash registers. Buy such paper will not be difficult;
In this case, the scheme does not allow the use of conventional thick wiring, otherwise it will begin to overheat strongly;
The secondary winding must be made by using three layers of tin;
Fluoroplastic tape is used to isolate each layer of tinned from each other;
At the exit with your own hands it will be necessary to solder ends - contacts from the secondary winding. This is necessary in order to increase current conductivity;
In the inverter housing, be sure to provide the fan. It will serve as a plungery mechanism that reduces equipment overheating.

Setting inverter

Problems with the work of cedar 160, Kaiser Mig 300 does not occur. Cedar 160 and Kaiser Mig 300 are factory equipment that has excellent specifications. These semiautomatics function perfectly, allow you to receive required amount Ampere - 160 amps, 170, 190 amps, etc. It all depends on how you configure the device.

But if you decide to remake the inverter and make a semi-automatic one from it, then the idea with the purchase of cedar 160, Kaiser Mig 300 should be thrown away.

After completing the work with the transformer, you should move to the inverter. To do correct settings The inverter itself, alteration will bring the desired result. And because homemade semi-automatic will function not worse than the finished apparatus of cedar 160, Kaiser MIG 300.

Be sure to pride the presence of highly efficient radiators used for rectifiers (input and output) and strength keys. Without them, the device can not really work.
Inside the radiator housing, which heats up most of all, the thermal sensor should be installed to trigger it in case of overheating.
Power part Connect to the control unit and turn on the working network.
When the indicator is activated, the oscillograph should be connected to the wires.
Lay two-polar impulses. Their frequency is ranging from 40 to 50 kHz.
Time parameters between pulses are adjusted by changing the input voltage. The time indicator must correspond 1.5 μs.
Make sure that the inverter gives the rectangular pulses on the oscilloscope. Fronts should not exceed 500 ns.
When the device was checked, connect it to the power grid.
The indicator embedded in the semi-automatic manner should issue 120 amps. Parameters can reach 170, 190 amps. But if the device does not show this value, you will have to go to search for the causes of low voltage in the wires.
Typically, such a situation occurs when the voltage is less than 100 V.
Now we test the welding semiautomatic device, the starting device with the changeable current. At the same time, constantly monitor the voltage on the condenser.
Complete testing test indicators.
Check how the device behaves in the case of a loaded state. Similar primary tests should be held with cedar 160 and kaiser MIG 300. Although Kedar 160 and Kaiser MIG 300 are factory semi-automatic sediments from proven manufacturers, make sure their professional benefits will never be superfluous.
To check the self-made inverter or cedar 160 with Kaiser Mig 300, you need to connect a loading retail to the welding wires by 0.5 Ohm. Make sure that this element is withstanding the load of more than 60 amps. Voltmeter controls current parameters.
If the semi-automatic check showed that the specified current value and the controlled value differ, it will be necessary to change resistance. Do it until you reach a positive result.

Collect the device that will perform a full-fledged analog for cedar 160 and Kaiser Mig 300 is not so simple, but perhaps. You ourselves define, there will be a semi-automatic to issue 120 or all 190 amps. Make the choice of the factory model is easier. But the price is appropriate. The price of the same semi-automatic cedar 160 MiG is from 27 thousand rubles. But the decision to take you.

Among beginners and professional welders welding semiautomatic inverter type It is the most popular device. For first, it provides ease in acquiring welding skills, the second gives performance and a large set of additional settings.

Semi-automatic welding equipment can be useful practically for any welder, but has a rather high cost. In the presence of manual arc welding, it can be converted into a semi-automatic inverter type.

The semi-automatic welding machine is initially provided for working with a twisted wire in the protective gas environment (inert or active). His difference from the conventional handheld arc welding apparatus is the presence of a wire feed mechanism, a gas cylinder, a special burner and a gas control unit and additive.

The power source itself in the form of an inverter is no different. If the feed mechanism is built into the inverter housing, then there is an optional wire connector.

Therefore, many holders of manual arc welding devices over time, a desire arises to expand their capabilities and make homemade semi-automatic. It is possible to implement it very easily. There are several implementation options, which one to choose depends on the availability, time and desire.

Multifunctional devices

Part of the manufacturers of manual arc welding inverters, given the wishes of buyers, provided for the required additional connectors. They help as quickly as possible to redo the device in a semi-automatic.

Some models of inverter devices like "source" on the rear panels have a key to switch the operation mode from MMA to MIG and a connector for controlling / disable inverter. It is usually completed with an europal 3 m long with a burner at one end and a connector on the other.

The connector allows you to feed the welding wire and protective gas, in addition, the cable is passed through it to supply control signals to the electric motor of the additive and gas connections.

There is a special cable for connecting to the inverter. It must be attached to the connector through which the welding current from the inverter came to the electrically conductor. Now, in a semi-automatic, it will come on a MIG burner.

The second cable nourishes the feeding mechanism from the inverter if it provides the appropriate connector, or from another low-power source. direct current 12 V.

Before work on the gas cylinder, the required gas consumption is set, and on the mechanism of broaching the rate of supply of the additive. The inverter is set to the welding current, the value of which depends on the thickness of the welded metal.

Then proceed to welding. As we can see, the transformation of manual arc welding in the semi-automatic does not need alterations, just buy missing equipment. The only drawback is that the inverter will be with the prefix device broach.

Almaty device

In more difficult case The manufacture of a semi-automatic consists of the alteration of an inverter of arc welding and creating a device for pulling from undergraduate materials. If you had to repair the inverter device, you can safely implement the implementation of the second option.

A system unit is ideally suitable as a system unit for a device for pulling a semiautomatic device of an inverter type. It is quite easy to open, while roomy and durable.

This will simply adjust the clips of the rollers and install a reel with a wire. In favor of the system unit and the fact that it is easy to make holes in the right places, and there is a built-in 12 volt power supply. It is needed to power the driving of the additive and the gas valve.

For the desired fasteners, it is necessary to make layouts of embedded components from infirred materials and try inside the box. Making sure the correctness of the selected layouts can begin the manufacture of fasteners.

The coil for semi-automatic can be purchased ready or do it yourself. In production it is very simple. The diameter of the cheek should be 200 mm, and the cylinder on which the wire will be filled, have a diameter of 50 mm so that the plastic pipe can be applied as an axis with the same face value.

For the feed mechanism, two clamping and one guide roller will be required, the spring. The use of electric motor from janitors is possible as a pull engine. As a base on which the details will be attached, you need to use a metal three-millionth sheet.

In the plate in the right places, the holes for fastening the rollers and the shaft of the electric motor of the future semiautoma are drilled. Since one roller clamping, the hole for it is drilled by an oblong shape.

The pressure spring will be pressed on top of it, the force of which is adjusted through the screw. Roller and bearings are mounted on one side of the plate, and the engine on the other. A feed roller is planted on the motor shaft.

The resulting device is installed inside the system unit so that the place of alignment of the rollers and the axis of the MIG burner mig was in the same plane. This will prevent the wire hall when stretching. To adjust the additive when unwinding, the tube is installed before the rollers.

Node control

For supplying gas and additives to welding semiautomatics will be required:

2 relays;
diode;
PWM regulator;
capacity with transistor and resistance;
solenoid valve;
wires.

The valve is required for gas flow into the welding zone. All components can be purchased at the sale of used parts.

Control schemes in the semi-automatic inverter type can be different, but the essence of them is simple and is as follows.

When you press the button on the burner, both relays are switched. The first supply voltage to the gas opening valve.

The second relay feeds the power to the wire feed motor. But its inclusion occurs a little later due to the low frequency filter in the form of the RC chain formed by a condenser and a resistor.

Sometimes it takes a wire broach without gas supply. For this incident, an additional button is provided that provides a break, bypassing the gas relay.

Self-induction from the valve is removed if you connect a diode. To power from the MIG inverter, the burner must be installed next to the euro the connector is optional through which the current will arrive.

When the button is turned on, the gas flow begins on the burner, after a while the additive is supplied. The delay time is regulated selected suites and resistor rates. A pause in a semi-automatic inverter type is necessary to protect the welding bath from the effects of atmospheric air.

When the button is turned on, the voltage enters the container. Gradually, it charges, when a certain value is reached, the transistor is opening, which causes the relay inclusion.

Burner

The burner for the inverter welding semiautoma can also be made itself, but it's easier to purchase inexpensive model With sufficient welding current.

With independent manufacture, the euro is still required. The connector and the feed cable, if we want to obtain the welding semiautomatic agent of aesthetic species. In addition to the welding current, you need to consider the length and flexibility of the hose.

Excessive softness of the hose leads to the inflection and, accordingly, to braking the wire. A good supplement is a spring or a powerful rubber seal in the location of the hose with a burner and a connector. This will not allow him to break in these places.

Inverter

Inverter manual arc welding is also required to remake. Although it can be used without alterations, but the welding quality will then be lower than that of factory welding semi-automatic devices. It's all about the voltampear characteristics. The difference is insignificant, but it affects.

To eliminate these differences, you will need a toggle switch, three resistance, one of which is variable.

To adjust the characteristic, you must install a divider in front of the shunt that controls the current. Due to the change of divider parameters, adjustment will occur. The toggle switch is needed to switch the operating mode of the inverter from the manual arc in MIG.

As a result of the refinement of the inverter and independent manufacture Device feeding wires, a semi-automatic type welding equipment is obtained with good parameters. At the same time save money and get a lot of pleasure from what they all did.

If you have to engage in professional welding, it is better to buy a ready-made semiautomatic. To date, the choice of these devices is wide, and it is quite possible to choose a budget model of acceptable quality.

Most welding machines, especially homemade, are very far from perfect. We offer a scheme for the adjustment of the self-made welding machine from the "change" in the "constant" with your own hands and you can use electrodes of any type ( see rice. one).

Fig. 1 scheme of the welding machine with a highly efficient inductive capacitive filter that smoothes the ripples of the straightened voltage.

"Walk" according to the scheme.

Choke L.

The core for him is taken from the choke of downtown Lighting 1N400N37-110. Removing old windings, you need to save cardboard pads that provided the gap between the main and closing parts of the core (Fig. 2).

When re-assembling them are installed in place. The new winding is wound only on one side rod, three layers of the copper tire with a cross section of 4x6 mm, located evenly along the entire length of the core. The beginning of the throttle winding is connected to the condensers block C1 ... C6, and the end of the winding is to the terminal "+" (Fig. 1).

Rectifier and filter condenser block.

Diodes U01 ... U04 type D161-320 or similar, calculated on the average rectified current - above 250 A and reverse voltage - at least 200 V, mounted on standard cast radiators-coolers, which must be isolated from each other and from the welding housing Apparatus with textolite plates. Condensers 31 ... 56 - electrolytic, type K50-3 or K50-7 two-section 250/290 (150 + 150 μF). The total capacity of the condensers block is 1800 microf. Establish their most convenient in one row on the textolite plate with a thickness of 4 ... 6 mm.

The regulator of the welding current P ("ballast rheostat").

Made from one section of restrictive resistance bridge crane DEC-256. (Fig. 3).

This resistance is ceramic truma with curly spiral groove on external surface, which contains a tire of a material with a high resistance, cross section of about 20 mm2.

The welding semiautomatic is a pretty popular device among professional and home masters, especially those who deal body repair. This unit can be purchased already in the finished execution. But many owners of welding inverter devices are asked: Is it possible to redo the inverter in a semi-automatic in order not to buy another welder? Make a semi-automatic inverter with your own hands - the task is quite complicated, but with a strong desire quite feasible.

For the assembly of the unit, the following elements will be needed:

inverter welding machine;
burner as well as special flexible hoseinside which the gas pipeline guides is held, power cable and electrical control cable;
mechanism for uniform automatic wire feed;
control module, as well as engine speed controller (PWM controller);
a cylinder with protective gas (carbon dioxide);
electromagnetic valve for gas cutting;
coil with electrode wire.

To assemble a homemade semi-automatic welding inverter, the latter must produce a welding current of at least 150 A. But it will have to be slightly upgraded, since the inverter voltamper characteristics are not suitable for welding electrode wire in the protective gas environment.

But about this later. First you need to make a mechanical part of the semi-automatic, namely the wire feed mechanism.

Electrode Wire Feed Mechanism

Since the feeding mechanism will be placed in a separate box, then for this purpose it will be perfect case from computer system. In addition, you do not need to throw out the power supply. It can be adjusted for the operation of the mechanism of broach.

To begin with, you need to measure the diameter of the coil with wire or, finding it on paper, cut the circle and paste it into the case. Around the bobbin should be enough space to accommodate other nodes (power supply, hoses, and wire pulling mechanism).

The wire feeder is made from the engine cleaner mechanism from the car. It is necessary to design a frame that will also hold the clamping rollers. The layout must be drawn on a dense paper in real scale.

Tip! The connector for connecting the burner hose and the hose itself with a burner can be made with your own hands. But it will be more correct to buy ready setwhich has an affordable price.

The feeder must be installed in the housing so that the connector is located in a convenient location.

So that the wire is fed evenly, all components must be fixed exactly opposite each other. The rollers must be centered relative to the opening for the input fitting, which is located in the connector for connecting the hose.

As roller guides, you can use suitable diameter Bearings. On them with turning machine A small groove is cleaned, which will move the electrode wire. For the housing of the mechanism, you can use the phaneer with a thickness of 6 mm, textolite or durable sheet plastic. All items are fixed on the basis of as shown in the following photo.

As the primary guide for wire is used drilled along the bolt axis. As a result, it turns out the similarity of the extruder for wire. At the entrance of the fitting dresses a cambrick, reinforced spring (for rigidity).

Rods on which rollers are fixed, also spring. The clamp of the clamp is installed with a bolt, located below, to which the spring is mounted.

Tip! If for any reason you have no opportunity to make a mechanism for pulling a wire with your own hands, then you can buy it in China. There are 12 V and 24 V mechanisms on sale in this case, since it is used from a computer from a computer, a device with power from 12 V.

Foundation for fastening Bobbin can be made of a small piece of plywood or textolite and pruning plastic pipe Suitable diameter.

Mechanic Management Scheme

To achieve good quality Seam during welding, it is necessary to ensure the supply of wire with a certain and constant speed. Because the engine feeder corresponds to the feeder from the wiper, then a device that can change the speed of rotation of its anchor is required. For this suitable ready decisionwhich can also be purchased in China, and is called it

Below is a scheme from which it becomes clear how the speed controller is connected to the engine. The controller controller with a digital scoreboard is excreted on the front case panel.

Next, you need to install relay, manager gas valve . It will also manage and start the engine. All data items should be activated when you press the start button located on the burner handle. In this case, the gas supply to the place of welding should be ahead (approximately 2-3 seconds) the start of the wire supply. Otherwise, the arc will sound surrounded by atmospheric air, and not in the protective gas environment, as a result of which the electrode wire melts.

The delay relay for self-made semiautoma can be collected based on the 815th transistor and condenser.. To get a pause for 2 seconds, there will be enough capacitor for 200-2500 Igf.

Tip! Since the power comes from a computer BP, which gives the voltage of 12 V, instead of independent manufacture of the module, you can use a car relay.

It is accommodated anywhere where it will not interfere with the operation of moving nodes, and is connected to the chain according to the scheme. You can use the air valve from GAZ 24 or buy a special, intended for semi-automatic. The valve is responsible for the automatic supply of protective gas to the burner. It turns on after pressing the start button located on the semi-automatic burner. The presence of this element saves gas consumption significantly.

But as already noted, for the full operation of the semi-automatic, the inverter is not suitable for the full operation of the semiautom. Therefore, that the semi-automatic prefix worked in a pair with an inverter, in his electrical circuit It is required to make minor changes.

Changes in inverter

To change the inverter flux, there are many schemes, but the easiest way to do this is as follows:

collect the device using chokes from daylight lamp according to the scheme below;

to connect the collected device, you will need to assemble another block according to the following scheme;

to the inverter did not work the overheating sensor, it is necessary to solder (parallel) to it, as shown in the following scheme.

But if the welding current control in the inverter occurs with the help of Shuntathen you can collect simple schema Of the three resistors and mode switch, as shown below.

As a result, the alteration of the welding inverter in the semi-automatic will cost 3 times cheaper than the finished aggregate. But of course, for self-assembly The device will need to have certain knowledge in the radio.