Type-setting welder for any power. Encyclopedia of radio electronics and electrical engineering

Encyclopedia of radio electronics and electrical engineering / welding equipment

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Almost everyone who has encountered metal work in his work dreams of having a welding machine "at hand". It would be nice to have both an electric arc and spot welding machine in one design, since thin metal cannot be welded using an arc, and thick metal using a spot method. But to make such an apparatus, if there are no powerful diodes "at hand", transformer iron of the required standard sizes and a winding wire with a large cross section, is almost impossible. This article will help you find a way out of this situation, and even with the lowest material costs.

The proposed welder is made from several transformers from old TC270 tube TVs. The advantage of the design is that this approach allows increasing the power of the welding machine depending on the necessary welding conditions, there is no need to rewind the primary winding, and the secondary winding is wound from wires folded in parallel from the demagnetization loops of the same TVs, which allows the use of low-current (10.. .20 A) power diodes.

The author's design of the welding transformer consists of six rewound transformers TS270, the primary windings of which are connected in parallel, and the secondary windings are connected in series if a welder is needed for electrode welding, and in parallel if spot welding is required. The power of this transformer is approximately 3,5 kW. If less or more power is needed, then the number of transformers is reduced or added accordingly.

All transformers are disassembled, the primary winding is left unchanged, and the secondary windings and shielding foil are wound up. If it is supposed to weld with an electrode with a diameter of 1,5 ... 2 mm at a current of 25 ... 70 A, then 2-3 transformers are enough, if with a diameter of 3 mm at a current of 90 ... 140 A, then 4-6 transformers, if with a diameter 4 mm at a current of 160 ... 190 A, then 7-8 transformers. To improve the ignition of the arc, the voltage on the secondary winding is chosen to be 60 V.

In this case, all the basic information for winding transformers will correspond to those given in the table. Winding data are given for half windings. If a wire of a different diameter is used, then the total cross section should be equal to that given in the table. Before winding, prepare the harness as follows: install a vice on a workbench and clamp, for example, a screwdriver in them, then measure the distance given in the table (the length of the half-winding wire), and fix the second vice.

Now you can make a harness with the desired number of cores. If the wire was taken with damaged insulation (for example, it was wound from deflecting systems), then it must be wrapped with woven tape or tape on a woven basis. Such a transformer can be used either for AC welding, or possibly used with a powerful single bridge. The bundle prepared in this way is wound on the frame, the ends of the bundle are cleaned, the conductors are divided by the number of diode bridges, called with an ohmmeter and the resulting amount is twisted together. The second half-winding is made in the same way, then the transformer is assembled. The rest of the transformers are made in the same way and mounted on a metal frame.

In order to be able to use this unit for spot welding, it is necessary to make a mounting plate. It is a textolite board with sockets rated for a current of 10 ... 20 A, into which adapter boards with plugs are inserted, depending on the operating mode of the welding machine. The conclusions of the windings are connected according to the scheme of Fig.1.

(click to enlarge)

If powerful diodes for 160 ... 250 A are available, then adapter boards can be simplified by placing jumpers between the transformers. To adjust the welding current, you can turn off the primary windings of unused transformers, and they will act as chokes, the arc will be more stable.

As SA1, you can use an automatic machine for 30 ... 50 A, SA2-SA6 - any switches for 5 A, 250 V. You can use any diodes for a current of 10 ... 30 A, you only need to take into account the number of diode bridges according to the table.

When using diodes of types KD213, KD2997, KD2999, you can use the radiator shown in Fig. 2.

Before assembly, the diodes must be lubricated with thermally conductive paste.

It should be noted that if it is possible to use diodes connected in parallel, in this design, preference should be given to sufficiently powerful diodes, since if several diodes fail, say, due to thermal breakdown, the load on the rest increases many times and their failure is possible.

Instead of TC270, it is undesirable to use TCA270, since their windings are made with aluminum wire.

Author: S.M. Abramov

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