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ENCYCLOPEDIA OF RADIO ELECTRONICS AND ELECTRICAL ENGINEERING Small welding machine. Encyclopedia of radio electronics and electrical engineering
Encyclopedia of radio electronics and electrical engineering / welding equipment A radio amateur needs not only transistors, capacitors, microcircuits. Often it is simply necessary to have even such a device as a welding machine. But they are usually huge and heavy. However, there is a way out if the device is made according to the description in the magazine "Inventor and Rationalizer". Here is what the author writes about him. “I think you will be interested in a portable welding machine weighing only 26 kg. The supply voltage of industrial welding machines is 380 V, which is not always convenient and always unsafe. , in the form of a donut. I took two cores from LATRs, on the inside of each I unwound a part of the steel tape that forms the core, so that the donut hole became larger, and placed the primary winding of the transformer W1, as shown in the figure. So that the cross-sectional area of the core does not change, before installing the winding, I wound the removed part of the steel tape on the outside of the donut core. I selected the wire for the primary and secondary windings based on the fact that the welding current is 80 A, that is, it can be welded with a three-millimeter electrode. So I got a compact and fairly light welding transformer.
The second task is to achieve smooth regulation of the welding current, for which it is necessary to be able to change the secondary voltage. This is especially important when the welder is working far away from the mains and wants to increase the voltage to compensate for losses in long wires. In industrial welding machines, the voltage is roughly regulated, stepwise, by switching the windings. I supplied mine with a voltage rectification circuit built on thyristors (see diagram). For reliability, I took thyristors for a working current twice the current of the welding machine. At the output of the device, I received a rectified regulated voltage of up to 50 V. The output data of the device made it possible to use it for charging batteries. If the output terminals are connected to the battery, it will help start the car. Since the device is easy to carry, it can also be used as a source of direct current, if somewhere far from the mains you need a soldering iron or other tool with a voltage below 50 V. The dimensions of the device are 400x220x220 mm, the frame is welded from aluminum corners 20x20 mm, aluminum panels 2,5 - 3 mm thick. Holes for ventilation are drilled in the top, bottom and front. A shelf is welded to the side wall, on which thyristors are installed. Their radiators are separated from the wall and frame by insulating sleeves.
The transformer can also be made on other hardware, for example, the ShL type. But then the volume of the transformer core will increase, and with it the entire apparatus, and the magnetic characteristics will be worse. When winding the secondary winding of the transformer, do not forget to cover both core rings with it, otherwise you will not get the desired voltage of 50 V at the output of the device. In the diagram, dots indicate where the windings begin. The correct phasing of the secondary and control windings is very important. If you want to expand the voltage regulation range, put a capacitor of the MBGO type at 10 uF at 160 V. The diagram does not show the machine on the side of the supply voltage 220 V. It is necessary both for turning the device on and off and for protection against overheating. I had an AP-50 automatic machine with a 40 A thermal release at hand. You can put any other automatic machine, as long as it fits the parameters. If you need to cook often, then in order to avoid trouble, buy a 40 A meter. I note that with a welding current of 80 A (three-millimeter electrode), a current of no more than 20 amperes is consumed from the network. In this mode, the machine can work for a long time. When welding with electrodes of a larger diameter, the welding time will have to be reduced. So, if you need to cook with a 5 mm electrode, then, having used up two electrodes, you will feel that the apparatus has overheated, and this is highly undesirable. Notes on the figure and scheme The primary winding W80 is wound on two round cores with a hole diameter of 1 mm in two sections of 240 turns each, a PETV-2 wire with a diameter of 1,6 mm. The secondary winding W2 is made of 20 mm PETPE wire. First 24 turns are wound, then another 24, and then the sections are connected in series. The W3 control winding is wound on any of the two core rings with a PEV-2 wire with a diameter of 0,35 mm. It is best to wind with two wires at once, and after making 24 turns, connect the two sections in series. The electrical circuit of the welding machine: R1 - unregulated resistance 10 Ohm, 10 W, R2 - adjustable resistance 1-2k, 10W. VD1,2 - diodes D226, VD3,4 - thyristors T160. S - batch switch for current up to 50 A. W1, W2, W3 - transformer windings. V - voltmeter. Capacitor C - 0,5 uF, 160 V. Literature
Publication: N. Bolshakov, rf.atnn.ru
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