Welder from ... nothing. Scheme, description

ENCYCLOPEDIA OF RADIO ELECTRONICS AND ELECTRICAL ENGINEERING
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Welder from ... nothing. Encyclopedia of radio electronics and electrical engineering

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Encyclopedia of radio electronics and electrical engineering / welding equipment

I have been designing welding transformers for a long time, so I have experience in this matter. I would like to offer readers my latest - as it seems, the most successful - development of a welding machine of an unusual design.

The peculiarity of this device is that the core for the transformer is a stator of an outdated asynchronous motor. The choice of the core is determined by the cross-sectional area of the stator - it must be at least 20 cm2. If such a condition is met, a stator from any asynchronous motor will do. Well, the cross-sectional area is determined as shown in the figure.

Welder from ... nothing
Rice. 1. The main parameters of the stator of an asynchronous motor, necessary for converting it into a transformer core: a - core cross-sectional height, b - core cross-sectional width, S - core cross-sectional area

I will mention that the most rational value of the cross section of the stator-core lies between the values of 20 cm2 and 50 cm2. In principle, cores with an area of \u20b\u2bless than 50 cm2 are also suitable, however, in this case, it will be necessary to reduce the wire cross section in the primary and secondary windings of the transformer, which will significantly reduce the power of the device and narrow its capabilities. Well, the use of cores with a cross-sectional area of \uXNUMXb\uXNUMXbmore than XNUMX cmXNUMX is also irrational: a transformer based on it turns out to be unreasonably bulky and heavy, and this is also not an advantage of a portable welding machine.

Removing the stator from the motor frame is not too difficult. To do this, use a hacksaw for metal and a small sledgehammer. To begin with, the front and rear covers are removed from the engine along with the anchor. Then, with a hacksaw, you need to make a couple of cuts in the way as shown in the figure. The cut needs to be as deep as possible, but try not to damage the stator. Just know: the deeper the cut is, the easier and without damage it will be possible to remove the stator from the housing.

Now hit hard with a sledgehammer next to one and the other cuts. As a rule, several blows are enough for the housing to fall apart and the stator with the windings to be freed from it.

Welder from ... nothing
Rice. 2. Preparatory operations for removing the stator from the motor housing

Burnt motor windings are usually unusable and will need to be removed with pliers and metal shears.

Having freed the stator from the winding, you will get a blank for the welding transformer core. It is only necessary to remove the jumpers of the grooves for the windings - and you will get a finished core. For this, an ordinary chisel and a hammer are used. It is most convenient to remove the jumpers first from one end, and then from the other. I warn you that you need to work in protective glasses, in an isolated room. Also make sure that there are no breakable objects nearby. Try to cut down the teeth as close to the base as possible and preferably evenly.

After removing the teeth, the core is wrapped with cotton tape - this will protect the first winding joint from breakdown on the body. It is convenient to wind the insulation using a special shuttle cut out of plywood, as shown in the figure. By the way, you will also need the same shuttle to wind the wire onto the core.

Welder from ... nothing
Rice. 3. Stator winding with cotton electrical tape: 1 - stator (transformer core), 2 - electrical tape, 3 - shuttle with electrical tape

The primary winding of a transformer is best obtained from cotton-insulated wire. Its cross section can be selected in accordance with table 1. For the secondary winding, a standard "core" in rubber insulation is suitable - such are used in power cables.

Table 1

Table 1 uses the following designations: S1 is the cross-sectional area of the primary winding; S is the cross-sectional area of the core, equal to the product of the height of the core and its thickness; W1 - number of turns of the primary winding of the transformer; W2 - number of turns of the secondary winding of the transformer; S2 - cross-sectional area of the secondary winding of the transformer; W3 - additional winding, wound with the same wire as the primary winding W, serves to adjust the welding current.

An additional winding W can have from two to five additional taps, but, in principle, you can do without it, leaving only a single winding W. In this case, however, the efficiency of the welding machine will deteriorate somewhat.

Welder from ... nothing
Rice. 4. Schematic diagram of the welding transformer

Welder from ... nothing
Rice. 5. DC welding machine

Welder from ... nothing
Rice. 6. Universal device for AC welding and DC car start

Welder from ... nothing
Rice. 7. Welding transformer design option: 1, 2 - power cables, 3 - transformer base, 4 - nut, 5 - threaded stud, 6 - transformer core, 7 - windings, 8 - top panel fixing screw, 9 - top panel, 10 - contactor (power socket), 11 - jumper (power plug with jumper), 12 - power cord, 13 - welding machine plug.

As can be seen from the transformer diagram, the welding current is regulated using the SA1 contactor. To do this, several ordinary network sockets are fixed on the instrument panel - their number is selected depending on the number of additional winding leads. The contactor is a mains plug, in which the legs of the connector are interconnected by a single-core wire, the diameter of which is 1/4 of the diameter of the primary winding wire. This makes it possible to use the contactor as a fuse that trips in case of unwanted overloads.

I would like to warn those who cannot get a wire for the primary winding of a suitable section that this is not a reason not to undertake the creation of a welding machine at all. It is quite possible to select several wires in such a way that their total cross section would be no less than recommended for W. In principle, you can even use bare wire by wrapping it yourself with cotton insulating tape. In the same way, you can select the wire for the secondary winding. By the way, this is exactly what I had to do in the manufacture of my welding machine. At the same time, it took ten skeins of narrow cotton tape to insulate the wire, which can be purchased at hardware stores or electrical stores.

After winding the primary winding, do not immediately fill the secondary winding - first you need to check it. To do this, the primary winding is connected to the network through a fuse, which is used as a piece of copper wire with a diameter of 0,1 ... 0,15 mm. If the winding does not buzz and does not heat up, this means that you have done the work with high quality and you can start winding the secondary winding. If the fuse burns out, this is a clear sign of a short-circuited coil. It follows from this that the primary winding will have to be rewound, paying special attention to the quality of the wire insulation. Well, if the winding does not heat up, but a rather loud buzz is heard, then this means that you made a mistake when counting the turns and you turned out to be less than Table 1 recommends. In this case, you need to rewind a few more turns and repeat the test.

In order for the welding machine to be universal, it is necessary to make a tap on the secondary winding from the third part of the turns and connect the transformer through it to a powerful diode rectifier - this way you get a "starter" for a car, which is especially convenient to use in the cold season, which will significantly extend the life your car's battery.

Please note that the use of powerful diodes with direct current of at least 200 A in the rectifier will allow you to weld parts with a DC arc - this gives better arc ignition and a smoother seam. If the value of the direct current of the diodes lies in the range from 50 to 200 A, then in this case a device is obtained for welding with alternating current and for starting the car with rectified current.

A properly assembled transformer does not require any adjustment and is ready for operation immediately after assembly. Of course, when performing welding work, it is necessary to observe all the precautions recommended when working with electrical appliances. In particular, it is forbidden to touch current-carrying areas; all switching modes of operation of the welding machine must be made only when it is disconnected from the mains. Welding work should be carried out in a special mask and overalls, avoiding splashes of hot metal and light radiation on open areas of the body.

Author: V.Druzhinin

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