Welding machine itself. Production of welding machines for home with their own hands. Features of homemade transformers

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.

In the arsenal of the home master there is a lot of tools for all occasions.

The welding machine is an indispensable device for real craftsmen. It can be bought in stores. However, more interesting and cheaper to assemble with your own hands.

Some have a welding machine that every craftsman dreams of.

It can be purchased in specialty stores today. Models There are many. Various accessories for the device and consumables are sold. Is it possible to make a welding machine with your own hands? The answer is simple: you can even need!

Types of welding machines

All apparatus for welding works are divided into gas and electric. Gas installations are not quite suitable for use in everyday life. They require a special relationship, as they are equipped with explosive ballons with gas. Therefore, we should only lead about electrical devices. They are different too:

The welding inventory is economical and perfect for home use.

1. Generators. These settings have their current current generator. They differ very large weight and bulky sizes. For home assembly and applications are not suitable.
2. Transformers. Such devices can be powered by a network of 220 or 380 volts. Especially popular, especially semi-automatic.
3. Inverters. Very economical devices, ideally suitable for home. Different with low weight, but rather complicated electronic circuit.
4. Rectifiers. Simple in manufacture and use. Even novice welders can make high-quality seams. Ideal for assembling with your own hands.

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How to start assembling inverter?

To assemble the inverter, you need to select a scheme that will provide the necessary parameters of the device. It is recommended to use the details of Soviet production. This is especially true for diodes, capacitors, transistors, resistors, chokes, thyristors and ready-made transformers. The equipment collected on these details does not require complex adjustment. All items are very compact on the board. For the manufacture of the device, you can select the following parameters:

1. The welding machine must operate with electrodes with a diameter of up to 4-5 mm.
2. The magnitude of the operating current is not more than 250 A.
3. Power supply - household network voltage 220 V.
4. Adjusting the welding current in the range of 30-220 A.

The welding machine consists of several blocks: power supply, rectifier and inverter.
Start to make your own hands the welding machine inverter type can be with winding the transformer in this order:

For assembly of the inventory, a ferrite core will be required.

1. You need to take a ferrite core sh8x8. You can use sh7x7.
2. The primary winding No. 1 consists of 100 turns wound by the wire of the PEV 0.3.
3. The secondary winding No. 2 is watched by a 1 mm cross section. Number of turns - 15.
4. Winding No. 3 - 15 turns of the wire of the PEV 0.2 mm.
5. Winding No. 4 and No. 5 consist of 20 turns of the wire with a cross section of 0.35 mm.
6. To cool the transformer, you can use the fan by 220 V, 0.13 A. These parameters correspond to the fan from the Pentium 4 computer.

So that the transistor keys worked uninterruptedly, they need to be submitted after rectifier and smoothing capacitors. The rectifier block is collected on a simple scheme on the board. All nodes of the welding machine are fixed in the housing. Well, if an appropriate case from a radiopreb will be in the household of the wizard, then you do not have to do it from the girlfriend.

On the front side of the case, there is a LED indicator that is noticed by its glow on the inclusion of the device to the network. Immediately you can install an optional switch of any type and a protective fuse. The fuse can be installed on the rear wall, as well as in the case itself. It depends on its design and dimensions. A variable resistance with which the operating current will be adjusted is also placed on the front side of the case.

If the electrical circuits are assembled correctly, everything is checked using a tester or other instrument, you can test the device.

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How to collect transformer apparatus?

The process of assembling the transformer apparatus for welding is slightly different from the previous version. It works on alternating current. For the welding of a constant current to it, the simplest console is assembled. To build the device, you need to get transformer iron for the core and several tens of thick copper tire or just a thick wire. You can search these things in the points of reception of non-ferrous and ferrous metal, friends and acquaintances. The core is recommended to do P-shaped, but it is possible round, toroidal. Some craftsmen successfully use the stator of the burnt electric motor as the core. For a P-shaped core, the assembly order may be:

To perform the primary winding, the winding wire will be required.

1. Dial the core from transformer iron to the optimal cross section of about 55 square centimeters. It is possible and more, but the device will be difficult. With a section less than 30 cm², the device may lose some of their qualities.
2. To perform the primary winding, a special winding wire is perfect for a cross section of 5-7 mm². It is made of copper, has heat-resistant fiberglass or cotton isolation. This is very important because when working the winding can be heated to a temperature above 100 degrees. Wire cross section is usually square or rectangular. It is not always possible to find such a wire. It is possible to replace it with the usual wire of the same section and modify: to remove the insulation, wrap the wire strips of fiberglass, soak in a thoroughly special electrical lacquer and dry. The primary winding consists of 200-230 turns.
3. For the secondary winding, you can first get 50-60 turns. Do not cut the wire. You need to enable the primary winding into the network. Find on the wires of the secondary winding the place where the voltage is equal to 60-65 V. In order to find this point, you have to wind or apply additional turns. You can wind aluminum wire, increasing the section 1.7 times.
4. The simplest transformer is assembled. It remains to place it in a suitable case.
5. For the conclusions of the secondary winding are made of copper terminals. A tube with a diameter of about 10 mm is taken with a length of 3-4 cm. Its end is split, and a hole is drilled in it, the diameter of which is 10 mm. To the other end of the tube you need to insert the end of the wire purified from isolation and enhance it with light blows of the same hammer. To enhance the contact of the wire with a tube-terminal, you can apply on it with core. The homemade terminals are screwed to the housing and m10 nuts and nuts. It is desirable to pick up copper details. You can, when winding the secondary winding, make taps every 5-10 turns of the wire. These taps will allow stepwise to change the voltage on the electrode.
6. It remains to make the electrode holder. It can be made of a pipe with a diameter of about 18-20 mm. The total length of it is about 25 cm. At the ends of 3-4 cm from the end, the excavations are cut up to about half a diameter. The electrode is inserted into the recess and presses the spring from the welded piece of steel wire with a diameter of 6 mm. To another end is attached to the screw and nut M8 of the same wire from which the secondary winding is made. A rubber tube of suitable internal diameter is put on the holder. Connect the device to the home network is recommended using a chipper and wires with a cross section of 1.5 mm² or more. The current in the primary winding is usually not above 25 A. In the secondary winding, it can be from 60 to 120 A. When working, it is recommended to take a break after 10-15 electrodes with a diameter of 3 mm to make a break so that the transformer is cooled. With more subtle electrodes, you can not do this. In cutting mode, breaks should be made more often.

In everyday life, especially in a rural output and country housing, there is a type of work on a mini farm, without which it is simply impossible to do. This is a compound or cutting of any iron, non-ferrous metals and aluminum (in a protective gas environment) with the help of electric arc welding. Hiring masters on them is more expensive.

What a welding machine is needed

Melts without welding will not collect any mechanical adaptation, nor mini-transport to facilitate work in the field, garden, garden, transportation is very much.

It is clear that the welder can not be in an instant, you need to learn or at least practicing professionals. And, of course, collect yourself or acquire a shopping device for an electric arge.

And our tips will help them orientize in assortment and models. Since this market is filled and reliable in work, but expensive, and cheap, but useless due to poor quality or for primitive welding.

Typification of electric arc apparatuses

Such household devices have such types:

• current varieties;
• three-phase 380 V.;
• inverter.

The most suitable devices for home assembly to people with small skills in electricity based on currents - constant and alternating.

Although the first current there are several variations, and in them a newcomer can be confused. We advise them for trained electricity.

And then consider how to make the welding machine with your own hands quickly and efficiently.

Transformers. These devices reduce the voltage and increase the current to form an electric arc. For example, instead of 220 volts, you get 17-45, but with a current to the six hundred amp (domestic welding you need not more than 160 amps, optimum - two and a half hundred).

Current adjustment is performed stepped. You can make a simple addition for this from high-voltage triodes and diodes with adjustable resistance. Or connect several turns of thick metal (copper) to reduce current. The scheme of the welding machine is shown on the site, you can consider both on the video.

In addition, they perform and second function - form a constant current with the help of built-in rectifiers also for welding work.

The greatest number of self-made are created on the basis of current transformation and voltage in one direction or another. Their properties are enough for uncomplicated electricity in everyday life.

Rectifier. It is also a welding unit, but for quality work and with a variety of metals. In everyday life is not made. And to acquire such a device, by the way, is not cheap, it is only for long-term welding processes and to create particularly durable seams.

For example, with large road traffic accidents with significant damage to the car body. Considering the subtle metal to not overheat and make the necessary compounds, not inferior to the factory.

Inverters (from English - converters). First of the classification of currents: there is a permanent (DC) and variable (AC).

Scientists, from Edisson and at least the famous Nikola Tesla, were interested in these transitions of one to another. So an inverter welding machine arose.

Current transformation in it is multiple. The amplitude current turns into a permanent one, and the one by means of a welding transformer is again either in DC or in AC.

Both, depending on which the scheme is configured, then turn into an electric argeum with a gradual change in its parameters in the desired ranges.

It is difficult to create it at home, but on sale - it is massive, despite the significant high cost.

What "cook"?

The current force depends on the tool that will produce welding - electrode.

Its thickness is tied to the thickness of the welded parts: if they are equal to five - six millimeters, the electrode should not be thinner than four. This is a maximum of homemade.

You can reduce the consumption of electricity if you boil the dimensions of thinner cores (up to one and a half cm). In this case, the current will decline five times.

Installation of the welded unit in the form of a transformer

This requires:

• a set of plates for a magnetic pipeline - in the bazaars from the burnt windings, buy cheap or disassembly;
• large wire on both types of windings.

The basis for them is steel plates not thinner a third of a millimeter. They are collecting them into a rectangle with a large internal space, where the primary and secondary winding should be placed from two vertical sides.

The number of turns depends on the steel frame area, to calculate it easily with a ruler and arithmetic. And the amount to divide in half.

The thickness of the wire is calculated according to such a scheme: the kilowatts of the welder are divided into two thousand and multiplied by one with thirteen hundred.

How the design of the welding machine is assembled. First, the primary winding is wound, start the layer on the layer, insulate the entire winding, output to the contact plate with four mounts: the beginning and end of the winding on the connection 220 V., Two more taps from 165 and 190 turns. Tires - current variators.

The secondary winding goes like this: out of 70 turns 40-41 are covered on top of the primary, the remaining coils go to the other side.

Its ends also output to Getinaks (textolite) - from here Plus and Minus will leave one on the welding lever, the second is on the welded item. The device is ready for work. Make a photo of the self-made welding machine.

During long-term operation, it is possible to repair a welding machine: the fastening tightening of plates (vibrate), contact plates.

Photo tips how to make a welding machine with your own hands

Work on the household always requires a certain set of tools, devices, as well as a variety of equipment. Especially acute this is felt by the owners of private houses and engaged in various types of repair in their own workshops and garages. The acquisition of expensive equipment is not always justified, since its use will not be permanent, but to collect the welding machine with their own hands, it is quite forces to each craft.

Before starting the process, it is necessary to determine the power of the device, because its dimensions and opportunities will depend on it. To familiarize yourself with the assembly procedure, you can view the appropriate video, where it is shown how you can make a practical welding machine. Its manufacturing will require some theoretical training, as well as experience of electromechanical work. The assembly of the electric device at home is made according to preliminary calculations, taking into account both the input and output parameters of the device.

This electrical apparatus is useful not only for welders performing at home or in the garage of some work, but also by conventional crafts that use a welding device for the construction of a variety of devices.

Features of homemade transformers

Self-collected devices differ from factory equipment by technical performance. Welding with your own hands is made of available elements and nodes, for which the welding transformer circuit is used. With accurate observance of the parameters of component parts, the electrel will last reliably for many years. Before making a welding transformer device with your own hands, you need to decide on the available component components. The basis is the transformer consisting of a magnetic pipeline, as well as primary and secondary windings. It can be purchased separately, to adapt the existing one or make it yourself. To make a welded electro appliance with their own hands, a transformer iron and wire for windings will be added to the variety of funds from undergraduate materials. The manufactured transformer should be able to connect to the household electrical power supply 220 V and have a voltage of about 60-65 V at the output to weld the thick metals.

Features of homemade rectifiers

Predially made rectifiers make it possible to perform welding of a thin metal with high quality of suture compounds.

The circuit of the welding machine that uses the rectification of the electric current is very simple. It contains a transformer to which the rectifier block is connected, as well as the throttle. This simple design provides sustainable combustion of welded electric arg. As a throttle, a coil of copper wires wedged on the core is applied. The straightening device is connected directly to the outputs of a lower transformer winding.

Depending on the purposes, you can independently construct a mini welded electro device. It perfectly cope with the metals of a small thickness that do not require the use of high currents when connected. From the welded electro apparatus you can make a spotter, which will significantly expand the possibilities of its use.

How to make a welding machine

The device for electric welding, manufactured personnel, is intended to perform small work on the house, the economy or in the garage. At the first stage, the necessary calculations are performed and the assembly parts and nodes are prepared. To assemble the welding transformer with your own hands, it is advisable to pre-decide on the place of assembling the device. This will streamline the manufacturing process. Near him there are layout nodes, allowing you to assemble the simplest electric welding machine. In addition to the main voltage converter, it will take a throttle that can be used from the elements of the fluorescent lamp. In the absence of the finished element, it is made independently of the magnetic pipeline from the powerful starter and the wires from the copper live in cross section of about 1 mm square meters. Handling welding electro apparatus will differ from their fellow not only as a view, but also characteristics. To decide how to do it, read similar devices in the photo or video.

Calculation of the welding transformer

Electric welding homemade fixtures are made according to the simplest scheme that does not provide for the use of additional nodes. From the required value of the welded electric flow will depend on the power of the collected electro apparatus. Welding in the cottage by an electrical device collected by their own hands will be directly dependent on the technical characteristics of its own product.

Making the calculation of power to welding, take the power of the required welded current and multiplies this value to 25. The resulting value at multiplication by 0.015 will show the necessary diameter of the cross section of the magnetic pipeline for welding. Before making calculations for windings, others will have to remember other mathematical actions. To get a summary of the highest voltage winding, the power value is divided into two thousand, after which is multiplied by 1.13. The method of calculations for primary and secondary windings is different.

To obtain winding values \u200b\u200bof the lower voltage of the transformer will have to spend a little longer. The value of the secting of the secondary winding depends on the density of the welded electric cooker. For values \u200b\u200b200 and it will be 6 a / mm square., With numbers 110-150 A - to 8, a to 100 A - 10. When determining the lower winding, the power of the welded electric coil is divided into density, after which is multiplied by 1.13.

The calculation of the number of turns is made by dividing the cross-section of the transformer magnetic pipeline by 50. In addition, the magnitude of the output voltage will affect the final result of the welding. It affects the characteristic of the process and may be increasing over the current, hollow or cool. This affects the fluctuations in the electrodes during operation at which the minimum current changes are important when working at home.

Scheme of welding transformer

The figure below shows the scheme of the welding transformer of the simplest view.

You can find electrical strokes that will be complemented by straightening devices and other elements to improve the welded electro apparatus. However, the main component is still the usual transformer. The activation scheme for connecting its wires is quite simple. Connecting a welded device is performed through a switching unit and fuses to household power supply 220V. The use of electrical power supplies must, as this will protect the network from overloads during emergency modes.

a - network winding on two sides of the core;
B - the corresponding secondary (welding) winding, included on the counter-parallel;
B - network winding on one side of the core;
G - the secondary winding corresponding to it, enabled sequentially.

Definition of parameters

To make an electric welding machine, it is necessary to understand the principle of operation. It converts the magnitude of the input voltage (220 V) to the reduced (up to 60-80 V). In this process, the low power of electric flow in the primary winding (about 1.5 A) increases in secondary (up to 200 A). This direct dependence of transformer operation is referred to as a low-type voltampear characteristic. The operation of the device depends on these indicators. On its basis, calculations are carried out, and the design of the future apparatus is determined.

Nominal mode of operation

Before making welding, it is necessary to determine its future nominal use mode. It shows which the time of adaptation for welding works, made with their own hands, can continuously cook and how much should cool. This indicator is referred to as the duration of inclusion. For homemade electrical apparatus, it is located in the area of \u200b\u200b30%. This means that out of 10 minutes it is capable of working continuously 3, and rest for 7 minutes.

Nominal working voltage

The operation of the transformer welded device is based on a decrease in the input voltage value to the working nominal. When making a welding machine, you can make any value of the output parameters (30-80 V), which directly affects the range of operating electrotocks. Unlike power supply power supply 220 V, the output value can also be about 1.5-2 volts in products for point electric welding. This is due to the need to obtain a high current level.

Network voltage and phase number

The current scheme for connecting a self-made welding transformer is calculated on the connection to a household single-phase power supply. For powerful welded devices, an industrial network with three phases is used by 380 V. from the magnitude of this input parameter and the other calculations are performed. Machine-made mini welding uses inclusion in a home power grid and does not require large supply voltage values.

Butterflow voltage

A household welder collected with their own hands must have a voltage value of x / x, sufficient to ignite the electric arge. The more this value, the easier it will appear. The manufacture of the device must comply with current safety standards that limit the output voltage to the maximum 80 V.

Nominal transformer welding current

Before making the electrical welding machine itself, it is necessary to determine the size of the rated current. It will depend on it the possibility of performing the works on the metals of various thickness. With household electric welding, it is quite sufficient to significantly in 200 A, which allows you to make a completely efficient device.. Exceeding this indicator will require an increase in the power of the electrotransformer, which affects both the growth of its dimensions and weight.

Assembly process

The manufacture of a self-made welding unit begins with the fulfillment of the required calculations. The values \u200b\u200bof the input and output voltage are taken into account, as well as the required value of the electric flow. From this directly depends the size of the device and the number of necessary materials. The electric welding machine, like the other equipment to make with their own hands is not very difficult. With the correct calculation and use of high-quality components, it will be able to reliably listen to dozens of years. For the base, a wire with copper veins is used, as well as a core from magnetically permeable iron. The remaining components are not so significant and can be seamless of those that can be easily delivered.

Where to start the preparatory stage

After performing the calculated part, materials are harvested, and the workplace is equipped under the assembly of the structure. To build a homemade welding machine, the wires are required to the primary, as well as the secondary winding, for the core - suitable transformer iron, insulating materials (lacket, textolite, glass beverage, electric circuit). In addition, you should take care of the winding machine for making windings, metal elements for the frame and the switching unit. In the assembly process you will need a set of an ordinary plumbing tool. Workstate Choose a refineral to wimble the coils and engage in the assembly process.

Build construction

By completing the preparatory activities, proceed directly to the manufacture of the electrical apparatus. Homemade electric welding requires a lot of time when assembling. It is not so heavy as long and painstaking, requiring accurate compliance with the calculated values. The procedure begins with the manufacture of a frame for windings. For this, the textolite plates of a small thickness are used. The inner part of the boxes should be suitable for a transformer core with a small gap.

After assembling two frames, it is necessary to make them iszing to protect the electric pipe. This is done with any electrical insulating material of the heat-resistant type (lacker, glass-behane or electrocarton).

A wire with heat-resistant isolation is wrapped on the resulting frames. This will protect the product from a possible breakdown when overheating in operation. It is necessary to accurately consider the number of turns so that the difference with the calculated values \u200b\u200bdoes not happen. Each wound layer is necessarily isolated from the subsequent. Between primary, as well as a layer of secondary winding, enhanced isolation is stacked. Do not forget to perform the necessary taps on the quantities you need. After completion of the winding, an outdoor islation is performed.

At the next stage, wound windings are satisfied with the transformer core, it is performed with a mixture (assembly of a single design). At the same time, it is undesirable when installing the sheets of transformer iron drill. Metal plates are connected in a chess order and are well tightened. Collect a simple welded apparatus of the P-shaped type with your own hands is not particularly difficult. Upon completion of the assembly procedure, the integrity of the windings is checked for their possible damage. The finish stage is the assembly of the case and the connection of the switching electro apparatus. Additional equipment includes a rectifier block, as well as an electric power regulator.

Carefully treat all processes, ranging from calculations and ending with self-made welding. From this will depend on the final parameters of the manufactured device.

The welding apparatus is used for some types of bodywork for connecting metal parts. However, working using these devices is usually produced in the presence of serious body damage, which are relatively rare. Therefore, to acquire a new relatively expensive device for one-time use is impractical. For household use, you can make a welding machine with your own hands.

Features

It should be borne in mind that the welding machine is made independently beneficial only if there are some source components. This is explained by the fact that, although collecting the simplest model of the device under consideration is easy, the materials required for this are very expensive. Therefore, if you purchase them individually specifically for the manufacture of this device with your own hands, at the final value it may be close to a new branded instrument, which, of course, will exceed the technical characteristics of the homemade welding machine.

Design

The basis of the tool under consideration is a transformer serving an energy source. It is two coils of copper wire wound on a metal core. Moreover, the coils differ in the number of turns. That of them, which connects to the power grid, is called primary. In the secondary coil at the same time there is a current of a lower voltage, but more ampera thanks to induction.

It should be borne in mind that the welding machine having a small current strength produces low-quality welding, while an excessively large current force leads to the combustion of electrodes and cutting metal.

The welding machine can be equipped with a transformer, for example, from a microwave oven. However, since there is a voltage of about 2,000 volts on its secondary winding, it is necessary to make some changes to the design with your own hands in order to reduce the voltage, namely to reduce the number of turns.

To reduce the voltage, the secondary winding is sawed in two places and pulled out from the coil. It is necessary to abide care, so as not to damage the primary winding. The secondary winding is then rewinding with a thicker wire or a PEV wire with enamel insulation or a thermal paper with a thickness of 0.05 mm. It is advisable to use the third option, as it avoids the occurrence of the skin effect manifested in the case of the use of a conventional wire. It consists in the displacement of high-frequency currents, which leads to overheating of the conductor.

The created winding is covered with thin insulating varnish. Parameters such as the number of turns and thickness are calculated for each transformer model. However, the optimal values \u200b\u200bare derived: the winding thickness is 0.3 mm, the width is 40 mm, the thickness of the wire is 0.5-0.7 mm.

If there is no transformer from the microwave oven or any other instrument, you can collect it with your own hands. This requires a cross-sectional core of 25-55 cm² from transformer iron, which is high magnetic permeability, a copper wire of several tens of meters long, insulating materials.

As for the wire, the best option is the thermal-resistant wire made of copper with fiberglass, x / b or in extreme cases with rubber insulation. You can make isolation on your own. To do this, you need to cut the insulating material with strips of 2 cm and wrap the wire.

The final stage is impregnated with electrical lacquer. The better the insulation, the lower the possibility of overheating tool. Winding parameters are calculated based on the instrument specifications. The output voltage of the idle stroke of the self-made welding machine ranges from 60 to 65 V, the operating voltage - from 18 to 24 V. at the highest power and electrode with a diameter of 4 mm power in the secondary winding is 3.5-4 kW, in primary - about 5 kW , taking into account losses. The current is about 25 A.

The number of turns are determined on the basis of voltage based on the area of \u200b\u200bthe core section of the magnetic pipeline in 2 cm. 1 V with a high-quality wire accounts for 0.9 - 1.1 turns. The total amount is obtained by dividing the voltage level. In this way, calculate the indicators for both windings. On the basis of this, it is possible to determine the required length of the wire by multiplying the length of one turn on their total number. At the same time you need to take some stock.

Before winding the coils you need to make frames from textolite or electrical cardboard, which are freely put on the core. Between primary and secondary windings, it isolated in the form of fiberglass, electrotechnical or ordinary cardboard.

Housing

The welding machine should be equipped with a housing in which the transformer is placed to preserve from exposure to external factors. When it is selected or manufactured, it is necessary to take into account that due to electromagnetic radiation, not all materials are suitable for this. The best options are considered solid rigid steel housing or a case of dielectric materials. The second option is harder to find or collect with your own hands, besides, it is less durable, but avoids vibration and energy loss in the structural elements of transformers caused by vortex currents, which are excited by strong magnetic dispersion fields near the windings.

In the housings from other materials, these negative phenomena can be somewhat reduced (by 30-50% depending on the design and material of the case), if you make longitudinal wigs on the body.

Most self-made welding tools do not have a solid body. This avoids such problems associated with it, like vibrations, vortex currents and energy loss. However, in this case, the welding machine is exposed to external factors, which leads to a sharp decrease in reliability and safety of work. In addition, it should be borne in mind that the aforementioned losses make up a few percent, which is almost unnoticed against the background of resistance in power lines and voltage fluctuations on the network.

In addition, it is desirable to equip the device to adjust the secondary voltage for smooth adjustment of the welding current. This will make it possible to compensate for losses in the wires of a long length, which is particularly relevant when working away from the supply network. In branded tools there is a stepped voltage adjustment by switching the windings. The home electric welding machine can be equipped with a voltage straightening circuit built on thyristors.

Question of reliability

Welding apparatus, made by your own hands, is not so reliable as a corporate analog. Therefore, in the manufacture, some measures should be taken to increase it.

The main factor leading to the premature failure of the device under consideration is considered overheating. To reduce the possibility of its occurrence, first of all, it is necessary to make effective isolation. This requires reliable winding wires with a current density to 5-7 A / sq. Mm. However, this may not be enough.

For quick cooling, the wire needs to be interacted with air. To do this, the windings need to make gaps. After the first layer of the wire and every two subsequent from the outside, the hetaenax or wooden planks are inserted 5-10 mm.

Thus ensure the contact of each layer of wire with air on the one hand. If the welding machine does not have fans, the slots are oriented vertically to ensure permanent circulation of air. In this case, cold air goes from below, warm leaves up.

A more efficient option to ensure the cooling of the transformer of the welding machine, of course, is a fan. It blowings almost does not affect the speed of heating, but significantly accelerates cooling. However, it should be borne in mind that for a transformer with closed windings, the overheating problem will not be solved even when installing a powerful fan. In this case, it is possible to avoid only a moderate mode of operation.

There is another option to solve the problem of overheating of the transformer. It consists in immersion in transformer oil. This fluid not only removes heat, but also is an additional insulator. In this case, the transformer housing must be a hermetically tank.

The most problematic in terms of overheating are toroidal transformers. They are quickly heated and slowly cooled. Also, a rather serious problem of homemade transformers consider vibration arising during operation due to the attraction of metal elements by the variable magnetic field created by them. Because of this, there is friction of wires, which leads to the destruction of the insulation, as well as the destruction and maintenance of windings on the corners of the frame. To reduce the effects of the impact of vibration, it is necessary to make high-quality isolation. It is also necessary to firmly fix all fixed elements.

Storage and use of the welding machine in high humidity should be avoided. Water condensing in insulation creams is a current conductor. Before using the tool you need to check. If the voltage goes beyond 60 - 65 V, increase or reduce the winding.