In message <5.1.0.14.2.20050401134451.0beaa1c0 at localhost>
Tom Peters <tpeters at mixcom.com> wrote:
[ battery tab welder ]
Do you have a plan / schematic / organizing principle?
I'd live to be able
to build something like this myself, but the $425 price tag for the basic
power supply is out of reach for me. If I could build that, I could buy the
tips from these guys.
Well, as far as I can tell, the core of the welder is a 680,000uF 25V
capacitor (or a capacitor array), with some form of electronically actuated
switch (transistor or relay basically) to connect and disconnect the power
supply and a current-limited constant-voltage power supply. You also have an
SCR (or a solid state relay, or even a normal mechanical relay if you can get
one that's beefy enough) that switches the charger on and optionally a
voltage monitor. I'd use an L200C regulator for the power supply - it can
handle 1.5A and has current limiting and voltage regulation built in.
The HS300A2 welder seems to take 24V on the input, and has a power output of
around 110 watt-seconds. That seems to be easily reproducible - the only
really expensive parts are going to be the capacitors (I got mine from
Mainline Surplus Sales - <www.mainlinegroup.co.uk>) and the SCR or SSR. I'm
still trying to track down a nice, powerful SCR that can handle 1000 amps for
about 10mS.
As far as logic goes, all you really need to do is disconnect the power
supply when the trigger button is pressed. A simple transistor inverter
circuit should be sufficient:
Trigger sw. | SCR Power
---------------------------
0 | 0 1
1 | 1 0
That just leaves connectors - I don't recognise the connectors HSW used, but
I'd guess that they're standard medium-current power connectors.
If you really felt like skimping on cost, you could probably get a smaller
capacitor. I've only got one cap wired up at the moment and it's still
capable of welding two pieces of thin tinned copper wire together. I wonder
how well it would work for making Cu/CuNi thermocouples...
The only thing I really need now is nickel foil (sheet, shim stock, whatever
the proper name is), about 0.003" thick. McMaster-Carr sell it as order code
9707K33 - that's the standard NI200 alloy stuff used for battery tags. It's
$62 for a 6" by 50" length, assuming the website is accurate. I'm still
trying to track down a supplier in the UK. I found one that seemed to think
that ?50 for a 10cm square piece of 200 alloy nickel was a reasonable price.
$60 seems OK, but the shipping would probably be pretty expensive :-/
Later.
--
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