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ENCYCLOPEDIA OF RADIO ELECTRONICS AND ELECTRICAL ENGINEERING Manufacture of a small-sized welding transformer. Encyclopedia of radio electronics and electrical engineering
Encyclopedia of radio electronics and electrical engineering / Ham Radio Technologies Before a radio amateur or any homemade craftsman, the question arises of where to get a welding transformer for work that often occurs in the country and at home, which must be eliminated by welding. You can make a welding machine yourself. The manufacture of the welding transformer is done according to the method written earlier Production of a transformer for RA The requirements for this transformer should be as follows: - be small and easily portable - low current consumption when not welding or cutting. - the ability to weld with alternating current. - to ensure the use of frequently encountered brands of electrodes for welding - if possible, get as wide a choice of diameters as possible for the electrodes used, both for welding and cutting metal. All these requirements are dictated not by the ability to create something, but by the conditions that most radio amateurs and those involved in design have to face. To obtain a medium-weight core for your future welding transformer, plates 200 mm wide from oil-cooled transformer substations and 1,60 m long were used. The cross section of the transformer window is 150 cm square. For the primary winding of the transformer, it is necessary to use a wire with a diameter of 2,0-3,0 mm. For the secondary windings of the transformer, you need to use everything that you have at hand. It is advisable to use only that which has sufficient flexibility when winding. A copper bus with a cross section of 2x8 mm to 2x16 mm, 2x18 mm, 2x20 mm has proven itself well, it was wired from flexible cables with a cross section of 18, 20 square mm in rubber insulation. More other sections are quite rigid and difficult to wind on transformers of this type. First of all, everyone needs to decide under which electrode or under what diameters of the electrodes you need to make your cooking transformer, both weight and current will depend on this. We will assume that you want to cover as many common electrode diameters as possible and not be "locked" to one electrode diameter. To adjust the current of your transformer, adjustment was made according to pre-selected turns of the primary winding fig.
For winding for the network winding of the transformer, a wire of 2,5 mm was used, for the secondary winding a copper bus with a cross section of 2 x 12 mm was used. 250 turns are wound in the primary winding of the transformer, while the no-load current is 1,5 A. (the current of the primary winding of your transformer). After receiving a current of 1 ampere, it is necessary to wind the network winding to obtain a current of 100 mA. We need all this in order for our welding transformer to consume low current when connected to a 220V network. The current is selected at the rate of 100 mA, this is, firstly, a small current, and while you are preparing for welding, your meter will wind up very little, the entire main load is only for the time of welding or cutting. This is a good saving of your money especially in this unstable time. For the secondary winding, it is necessary to focus on a voltage of 40-50 volts. The number of turns is not given, as it all depends on the material you have. On this tap with a current of 1A (cutting), you will cut metal with a 4 mm electrode and with slightly worse characteristics with a 5 mm electrode. With a 3 mm electrode, cutting can be performed using the additional resistance used by welders, since when cutting, due to the high current after the electrode burns out by 50%, the electrode itself turns red, which leads to sticking in the event of a short stoppage of work. For welding under diameters of 5, 4, 3 mm, it is necessary to focus on the current under an electrode with a diameter of 3 mm. Why focus on an electrode with a diameter of 3 mm - this is the most common electrode for working with thinner metals and often used by radio amateurs for various types of welding of their structures. Any switch capable of withstanding current up to 20A can be used as a switch. Due to the high current when using electrodes of 4 mm and long work with electrodes with a diameter of 5 mm, you must remember to give your welding rest. For welding, standard or home-made electrode holders are used, which are easy to make for everyone. For good contact with the ground during welding, a home-made clamp was used, to which the "ground" wire is attached. Author: M. Gribak (UA9XEQ), ua9xeq@mail.ru; Publication: cxem.net
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