If you have the need to perform any uncomplicated welding work For household needs, it is not necessary to acquire an expensive factory unit. After all, if you know some subtleties, you can easily assemble the welding machine with your own hands, which will be discussed below.

Welding machines: Classification

Any welding machines are electrical or gas. It is worth saying that self-made welding machines should not be gas. Because they include explosive gas cylinders, it is not worth keeping this installation.

Therefore, in context self-assembly Designs will be discussed exclusively about electrical versions. Such aggregates are also divided into varieties:

1. Installation-generators are equipped with their own current generator. A distinctive feature is a lot of weight and dimensions. For home needs, this option is not suitable, and it will be difficult to assemble it.
2. Transformers are such installations, especially semi-automatic type, are very common among those who make welding equipment on their own. Food from the network in 220 or 380 V.
3. Inverters - such installations are easy to use and are ideal for home, the design is compact and weighs little, but the electronic circuit is quite complex.
4. Rectifiers - these devices simply collect and apply on purpose. With their help, even a novice can perform high-quality welds.

In order to assemble the inverter at home, a scheme will need to comply with the desired parameters. It is recommended to take details from the old Soviet devices:

Parameters for the device you can choose:

• It should work with electrodes whose diameter does not exceed 5 mm.
• The maximum operating current indicator is 250 A.
• Voltage source - household net at 220 V.
• Adjusting the welding current varies from 30 to 220 A.

The tool includes such components:

• power Supply;
• rectifier;
• inverter.

Begin with winding transformer And act in such a sequence:

1. Take a ferrite core.
2. Perform the first winding (100 turns by wire PEV 0.3 mm).
3. The second winding is 15 turns, wire with a cross section of 1 mm).
4. Third winding - 15 turns with a wire of a PEV 0.2 mm.
5. Fourth and fifth - respectively, 20 turns with wires with a cross section of 0, 35 mm.
6. To cool the transformer, take the fan from the computer.

In order for transistor keys to work continuously, the voltage should be served on them after rectifier and capacitors. Block rectifier Collect according to the circuit on the board, and all the instrument nodes secure in the case. Can be used old housing from radio device, And you can do it yourself.

From the front of the case is installed led indicatorwhich indicates that the device is included in the network. Here you can put an additional switch, as well as a protective fuse. It can also be installed on the back wall and even in the housing itself.

It all depends on its size and constructive features. A variable resistance is installed on the front of the housing, it can be used adjust the working current. When you collected all the electrical circuits, check the machine with a special device or tester and can test it.

The assembly of the transformer version will differ from the previous one. This unit operates on alternating current, but for a constant current welding you need to assemble a simple console to it.

To work you will need transformer iron For a core, as well as several dozen meters of thick wire or a thick copper tire. All this can be found in metals reception. The core is best done by P-shaped, toroidal or round. Many also take a stator from the old electric motor.

The instruction of the assembly of the P-shaped core looks like this:

• Take the transformer iron by section from 30 to 55 s m 2. If the indicator is larger, the device will be too heavy. And if the cross section is less than 30, the device will not be able to work correctly.
• Take the copper winding wire with a cross section of about 5 mm 2, equipped with heat-resistant insulation of fiberglass or cotton. Isolation is important because during operation the winding can warm up to 100 degrees and above. In the winding wire, the cross section is a square or rectangular cross section. However, this option is difficult to find. It is also suitable and the usual one with the same cross section, but only you will need to remove the isolation from it, wind fiberglass and thoroughly impregnate with electrical lacquet, then dry. In the primary winding of 200 turns.
• Secondary winding will require about 50 turns. Wire does not need to cut. Turn on the primary winding on the network, and on the wires the secondary find the place where the voltage is about 60 V. To search for such a point, wound up or wate the additional turns. The wire can be aluminum, but the cross section should be greater than for the primary winding, 1.7 times.
• Install the finished transformer in the case.
• To withdraw the secondary winding, copper terminals will be required. Take a tube with a diameter of 10 mm and about 4 cm long. Split its end and drill a hole with a diameter of 10 mm, and insert the end of the wire pre-purified from the insulation. Next, eat it with light hammer blows. To strengthen the contact of the wire with the tube-terminal, apply the core on it notches. Homemade terminals screw to the housing with nuts and bolts. Details best use copper. Having wrapping the secondary winding. It is advisable to make taps every 5-10 turns, they will allow you to change stepwise voltage on the electrode;
• For the manufacture of the electrically holder, take a pipe with a diameter of about 20 mm and a length of about 20 cm. At the ends of about 4 cm from the end part, cut the excavation to half the diameter. Insert the electrode into the excavation and press the spring based on the welded bush of steel with a diameter of 5 mm. At the second cone, attach the same wire that was used for the secondary winding, using nut and screw. Put on the holder the rubber tube with a suitable inner diameter.

The finished apparatus to the network is best connecting using wires with a cross section from 1.5 s m 2 or more, as well as the chub. The current in the primary winding usually does not exceed the indicator of 25 A, and in the secondary ranges in the range of 6-120 A. during operation with electrodes with a diameter of 3 mm every 10-15 make stops so that the transformer is cooled. If the electrodes are thinner, it is not necessary. More frequent breaks are needed if you work in cutting mode.

Mini welding with your own hands

To independently assemble the miniature welding machine, you will need only a few hours and such materials:

First neat disassemble the old battery And remove the graphite rod from it. At the end it will sharpen the skin and wipe the dry cloth. A piece of thick wire is a 4-5 cm from the end, clean from the insulation and with the help of the passage or side loops, start the loop. Insert the coal electrode into it.

Remove the secondary winding from the transformer and in its place mix thick wire 12-16 turns. Now all this is inserted into the appropriate case - and the device is ready.

His wires join the conclusions of the secondary winding, coal the rod is inserted into the loop And it is well crimped. Plus output Connect with electrode holder, and minus - with twin working parts. The holder handle can be adapted for the electrode.

You can apply the handle of the soldering iron or something similar. Turn on the device into the household network and execute connection of parts by means of graphite. There should be a flame, and on the end of the details a spherical weld is formed.

For the domestic workshop, the presence of the welding machine is very important. These devices have different designs and modifications. Both newcomers and experienced masters often prefer not factory, but self-made devices that can be modified to their own way.

In Arsenale homemade Masters There is a lot of tools for all occasions.

The welding machine is an indispensable device for real craftsmen. It can be bought in stores. However, more interesting and cheaper to assemble with your own hands.

Some have a welding machine that every craftsman dreams of.

It can be purchased in specialty stores today. Models There are many. Various accessories for the device and consumables are sold. Is it possible to make a welding machine with your own hands? The answer is simple: you can even need!

Types of welding machines

All apparatus for welding works are divided into gas and electric. Gas installations are not quite suitable for use in everyday life. They require a special relationship, as they are equipped with explosive ballons with gas. Therefore, we should only lead about electrical devices. They are different too:

The welding inventory is economical and perfect for home use.

1. Generators. These settings have their current current generator. They differ very large weight and bulky sizes. For home assembly and applications are not suitable.
2. Transformers. Such devices can be powered by a network of 220 or 380 volts. Especially popular, especially semi-automatic.
3. Inverters. Very economical devices, ideally suitable for home. Different with low weight, but rather complicated electronic circuit.
4. Rectifiers. Simple in manufacture and use. Even novice welders can make high-quality seams. Ideal for assembling with your own hands.

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How to start assembling inverter?

To assemble the inverter, you need to select a scheme that will provide the necessary parameters of the device. It is recommended to use the details of Soviet production. This is especially true for diodes, capacitors, transistors, resistors, chokes, thyristors and ready-made transformers. The equipment collected on these details does not require complex adjustment. All items are very compact on the board. For the manufacture of the device, you can select the following parameters:

1. The welding machine must operate with electrodes with a diameter of up to 4-5 mm.
2. The magnitude of the operating current is not more than 250 A.
3. Power supply - household network voltage 220 V.
4. Adjusting the welding current in the range of 30-220 A.

The welding machine consists of several blocks: power supply, rectifier and inverter.
Start to make your own hands the welding machine inverter type can be with winding the transformer in this order:

For assembly of the inventory, a ferrite core will be required.

1. You need to take a ferrite core sh8x8. You can use sh7x7.
2. The primary winding No. 1 consists of 100 turns wound by the wire of the PEV 0.3.
3. The secondary winding No. 2 is watched by a 1 mm cross section. Number of turns - 15.
4. Winding No. 3 - 15 turns of the wire of the PEV 0.2 mm.
5. Winding No. 4 and No. 5 consist of 20 turns of the wire with a cross section of 0.35 mm.
6. To cool the transformer, you can use the fan by 220 V, 0.13 A. These parameters correspond to the fan from the Pentium 4 computer.

So that the transistor keys worked uninterruptedly, they need to be submitted after rectifier and smoothing capacitors. The rectifier block is collected on a simple scheme on the board. All nodes of the welding machine are fixed in the housing. Well, if an appropriate case from a radiopreb will be in the household of the wizard, then you do not have to do it from the girlfriend.

On the front side of the case, there is a LED indicator that is noticed by its glow on the inclusion of the device to the network. Immediately you can install an optional switch of any type and a protective fuse. The fuse can be installed on the rear wall, as well as in the case itself. It depends on its design and dimensions. A variable resistance with which the operating current will be adjusted is also placed on the front side of the case.

If the electrical circuits are assembled correctly, everything is checked using a tester or other instrument, you can test the device.

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How to collect transformer apparatus?

The process of assembling the transformer apparatus for welding is slightly different from the previous version. It works on alternating current. For the welding of a constant current to it, the simplest console is assembled. To build the device, you need to get transformer iron for the core and several tens of thick copper tire or just a thick wire. You can search these things in the points of reception of non-ferrous and ferrous metal, friends and acquaintances. The core is recommended to do P-shaped, but it is possible round, toroidal. Some craftsmen successfully use the stator of the burnt electric motor as the core. For a P-shaped core, the assembly order may be:

To perform the primary winding, the winding wire will be required.

1. Dial the core from transformer iron to the optimal cross section of about 55 square centimeters. It is possible and more, but the device will be difficult. With a section less than 30 cm², the device may lose some of their qualities.
2. To perform the primary winding, a special winding wire is perfect for a cross section of 5-7 mm². It is made of copper, has heat-resistant fiberglass or cotton isolation. This is very important because when working the winding can be heated to a temperature above 100 degrees. Wire cross section is usually square or rectangular. It is not always possible to find such a wire. It is possible to replace it with the usual wire of the same section and modify: to remove the insulation, wrap the wire strips of fiberglass, soak in a thoroughly special electrical lacquer and dry. The primary winding consists of 200-230 turns.
3. For the secondary winding, you can first get 50-60 turns. Do not cut the wire. You need to enable the primary winding into the network. Find on the wires of the secondary winding the place where the voltage is equal to 60-65 V. In order to find this point, you have to wind or apply additional turns. You can wind aluminum wire, increasing the section 1.7 times.
4. The simplest transformer is assembled. It remains to place it in a suitable case.
5. For the conclusions of the secondary winding are made of copper terminals. A tube with a diameter of about 10 mm is taken with a length of 3-4 cm. Its end is split, and a hole is drilled in it, the diameter of which is 10 mm. To the other end of the tube you need to insert the end of the wire purified from isolation and enhance it with light blows of the same hammer. To enhance the contact of the wire with a tube-terminal, you can apply on it with core. The homemade terminals are screwed to the housing and m10 nuts and nuts. It is desirable to pick up copper details. You can, when winding the secondary winding, make taps every 5-10 turns of the wire. These taps will allow stepwise to change the voltage on the electrode.
6. It remains to make the electrode holder. It can be made of a pipe with a diameter of about 18-20 mm. The total length of it is about 25 cm. At the ends of 3-4 cm from the end, the excavations are cut up to about half a diameter. The electrode is inserted into the recess and presses the spring from the welded piece of steel wire with a diameter of 6 mm. To another end is attached to the screw and nut M8 of the same wire from which the secondary winding is made. A rubber tube of suitable internal diameter is put on the holder. Connect the device to the home network is recommended using a chipper and wires with a cross section of 1.5 mm² or more. The current in the primary winding is usually not above 25 A. In the secondary winding, it can be from 60 to 120 A. When working, it is recommended to take a break after 10-15 electrodes with a diameter of 3 mm to make a break so that the transformer is cooled. With more subtle electrodes, you can not do this. In cutting mode, breaks should be made more often.

It is no secret that the welding machine is your own hands for a person familiar with the electrical engineering, it's not so difficult to do. It makes sense, if it is intended for use in personal farm, where only from time to time applies. In this case, the self-made welding machine, the cost of which is much lower than the factory, is quite capable of replacing it. Details for its design freely can be removed from various electrical household devices, failed or, if necessary, manufacture and assemble. The schemes of such devices may be different. The decisive factor here usually performs the availability of parts and materials.

Choosing a suitable welding machine circuit

All welding machines of arc electrical welding are divided into inverter and transformer. Immediately it should be noted that the question of how to make a welding machine independently depends on the possibility of getting parts from a certain household appliances. If all parts are purchased at market prices, then as a result, the cost will approach the price of the company apparatus, yielding him in efficiency. That is why you need to have certain knowledge in the field of electrical engineering and know where which item is placed and where it can be removed for free or for a small price.

The number of turns on the primary winding must be about 240. At the same time, to ensure the possibility of adjusting the welding current in increasing from 20 to 25 turns, several taps are made. The secondary winding is wedged with a copper cross section from 30 to 35 mm in an amount from 65 to 70 turns. To adjust the welding current on it, too, you need to make taps. The isolation of the secondary winding should be particularly reliable and heat-resistant, so it should pay special attention. Each of the layers should be paved with additional insulation of cotton fabric.

The transformer welding machine can use an alternating or permanent current for operation. The first one is the easiest on the device, but more difficult to use. For a direct current, it is easy to modify, installing the diode bridge. Such a device is reliable, durable and unpretentious in use, but has significant weight and is sensitive to voltage drops in the power grid. If it falls below 200 V, it becomes very difficult to light and hold the electric arc.

Unlike the transformer inverter welding machine, due to the use of modern electronic parts, has a relatively small weight. It may well wear one person on his shoulder. Such an apparatus has a current stabilization device, which makes it easier to work in welding. A decrease in voltage for it is practically not creating no interference, and it can work from household power grid. However, the inverter apparatus is very sensitive to overheating and requires great caution in work, otherwise it easily fails.

Assembling transformer welding machine

The main part of such an apparatus is a transformer. The main characteristic of it should be the ability to keep the working current consistently, and this relies on such an indicator as the outer volt-ampere characteristics of the power supply. In other words, the current of welding should not significantly differ from the current produced by a short circuit.

For this, current must be limited to one of these methods as an increase in the magnetic scattering of the transformer, ballast resistance or installation of the throttle. The transformer itself can be removed from the burnt high-frequency microwave oven. If there is no access to it, you can make a welding transformer with your own hands.

For the manufacture of the core, you need to purchase plates from transformer iron. The core area ideally should range from 40 to 55 cm², with such indicators the winding will not be overheated. Primary windings for self-made welding transformers should consist of a thick heat-resistant copper wire with a cross section of at least 5 mm, and better more enclosed in fiberglass or cotton isolation. Plastic or rubber insulation for such purposes is not recommended for such purposes, since it is less than a stand for overheating and it makes itself easier, which causes a short circuit on the primary winding.

It should be remembered that the secondary winding of the welding transformer must be wound on both sides of the core. It can be connected either sequentially or counter-parallel. It should be remembered that the winding should be made on both sides in one direction. After that, the transformer is placed in a metal case. With its end, the holes are cut out for cooling the machine, and the exhaust fan is made, removed from the power supply of the outdated or broken computer. On the opposite side of the body, several dozen air circulation holes are drilled. After that, you can connect cables and a holder for electrodes.

How to assemble a homemade welding inverter?

Inverter welding machine can be completely collected from parts from old TVs. This requires some not only common electrical knowledge, but also certain knowledge in electronics. Its scheme is quite complex. The inverter is a pulse source of DC, and several ferrite cores are suitable for its manufacture, which are on lowercase transformers in old TVs. They add up three, and the winding from a copper or aluminum wire is already wound.

Since the primary winding is most susceptible to overheating, there must be small intervals between the turns to facilitate the cooling process. It is worth remembering that the aluminum wire must be taken to take a larger cross section than copper, since its thermal conductivity is lower. To fix the inverter windings, a wire bandage from a millimeter copper wire 10 mm wide, imposed on a fiberglass isolation is used.

Capacitors can also be removed from the TV, but only it is worth remembering that it is not recommended to take paper capacitors from low-frequency chains, because they will not work for a long time at such loads. Trinistors are better to take enough low-power and connect them in parallel than to take one powerful, because there is a large thermal load on them and it is easier to cool. Trinistrators are mounted on a metal plate with a thickness of at least 3 mm, which facilitates the removal of excess heat. Diodes for assembling a diode bridge also can easily be dial from several old TVs. The bridge itself is also mounted on the heat sink plate.

Some details for the inverter apparatus are absent in TVs, and they have to make them alone. First of all, it is a choke. It is not difficult to make it without a frame of copper wire with a cross section of at least 4 mm, screwed up with 11 turns with gaps of at least 1 mm. Since the primary load will fall on the throttle, you need to put an additional air cooling system. In this capacity, it is quite possible to apply the usual household fan mounted in the welding machine housing so that the air jet falls directly to the choke.

All elements of the electronic circuit are collected on pCB From a fiberglass, a thickness of at least 1.5 mm. The heat sink is joined by the board, facilitating the cooling of the entire system. In the center of the board, a round hole for installing the fan is cut, since without forced air cooling, the device will not work for a long time. The welding inverter mainly its advantage has the ability to make mini-welding work, welding thin metal sheets. The welding seam itself comes out more accurate than the transformer apparatus. It is crucial with this form of work as a car repair with your own hands.

The welding machine made independently includes the parts obtained for free or at a barn price, but it fully copes with its tasks.

The welding machine is a pretty popular device both among professionals and homemade masters. But for household use, there is no point in buying an expensive unit, since it will be used in rare cases, for example, if you need to brew a pipe or put a fence. Therefore, it will be wiser to make a welding machine with your own hands, putting a minimum amount of funds into it.

The main part of any welder operating on the principle of electric arc welding is a transformer. This detail can be removed from old, unnecessary home appliances and make a homemade welding machine from it. But in most cases a transformer requires a small refinement. There are several ways to make a welder, which can be both simple and more complex, requiring knowledge in electronics.

To make a mini-welding machine, you will need a pair of transformers removed from an unnecessary microwave oven. The microwave is easy to find friends, acquaintances, neighbors, etc. The main thing is that it has a power within 650-800 W, and there was a transformer in it. If the stove has a more powerful transformer, then the device will turn out with higher current indicators.

So, the transformer, filmed from the microwave, has 2 windings: primary (primary) and secondary (secondary).

Seconder It has more turns and a smaller wire cross section. Therefore, so that the transformer becomes suitable for welding; it is required to be removed and replaced with a conductor with large square sections. To remove this winding from the transformer, it is necessary to cut it on both sides of the part with a metal hacksaw.

It is necessary to do it with special accuracy to accidentally do not touch the saw of the primary winding.

When the coil is a spinal, its residues will need to be removed from the magnetic pipeline. This task will be much eased if drilled windings to remove metal voltage.

Do the same operations with another transformer. As a result, you will have 2 parts that have a primary winding at 220 V.

Important! Do not forget to remove current shunts (shown by arrows in the photo below). This percentage of 30 will increase the power of the device.

For the manufacture of secondary, it will be necessary to purchase 11-12 meters of wire. He must be stranded and have cross section of at least 6 squares.

To make a welding machine, for each transformer, it will be necessary to wind up 18 turns (6 rows in the height and 3 layers in the thickness).

You can braided both transformers with one wire or separately. In the second case, the coil must connect sequentially.

Winding should be made very dense, so that the wires do not hang out. Next, the primary windings need connect parallel.

To connect the details together, they can be screwed to a small cutting of a wooden board.

If measuring the voltage on the secondary of the transformer, then in this case it will be equal to 31-32 V.

This homemade welder is easily boiled by a metal with a thickness of 2 mm electrodes with a diameter of 2.5 mm.

It should be remembered that cooking with such a homemade apparatus follows with resting breaks, since its windings are heated greatly. On average, after each electrode used, the machine must cool for 20-30 minutes.

The thin metal unit made from the microwave will not work, as it will cut it. To adjust the current to the weld, you can connect a ballast resistor or choke. The role of the resistor can perform a segment of steel wire of a certain length (selected experimentally), which is connected to the low-voltage winding.

Variable Tock

This is the most common type of metal welding machines. It is easy to make it at home, and it is unpretentious in operation. But the main disadvantage of the apparatus is large weight of the lowering transformerwhich is the basis of the aggregate.

For home use, it is enough for the device to issue a voltage of 60 V and could provide current strength in 120-160 A. so for PermitTo which the household network 220 V is connected, a wire with a cross section of 3 mm 2 to 4 mm 2 will be required. But perfect option - This is a conductor with a cross section of 7 mm 2. With this section of voltage drops and possible additional loads, the device will not be scary. It follows from this that the renewer needs a conductor having 3 mm in diameter. If you take an aluminum conductor, the calculated cross section is multiplied by the coefficient of 1.6. For renewed It will take copper tire with a cross section of at least 25 mm 2

It is very important that the winding conductor is covered with rag insulation, since the traditional PVC shell is melted when heated is melted, which can cause inter-touch closure.

If you did not find the wire with necessary cross sectionthen it can make yourself Of the few thinner conductors. But at the same time the thickness of the wire will significantly increase and, respectively, the dimensions of the unit.

First thing, the base of the transformer is manufactured - core. It is made of metal plates (transformer steel). These plates must have a thickness of 0.35-0.55 mm. Studs connecting plates, it is necessary to isolate well from them. Before assembling the core, its sizes are calculated, that is, the size of the "windows" and the area of \u200b\u200bthe core cross section, the so-called "core". To calculate the area, the formula is used: S cm 2 \u003d a x B (see Fig. Below).

But from practice it is known that if you make a core with an area of \u200b\u200bless than 30 cm 2, then such a device will be difficult to get high-quality seam due to lack of power supply. Yes, and he will be heated very quickly. Therefore, the core cross section should be at least 50 cm 2. Despite the fact that the mass of the aggregate will increase, it will become more reliable.

For the assembly of the core it is better to use M-shaped plates And place them as shown in the following figure, while the thickness of the part does not reach the desired value.

Plates at the end of the assembly need to be copper (at the corners) with bolts, then clean the file and insulate with tissue insulation.

Now you can start winding transformer.

One nuance should be taken into account: the ratio of turns on the core should be 40% to 60%.This means that on the side where the primary is placed, there must be a smaller number of repetitions. Due to this, when welding welding, the winding having more turns will be partially disconnected due to the occurrence of vortex currents. This will increase the strength of the current, which will be positively affected on the quality of the seam.

When the winding of the transformer is completed, network cable Connects to the general wire and to the branch of 215 turns. Welding cables are connected to the secondary winding. After that, the contact welding machine is ready for operation.

Constant

To cook cast iron or stainless steel, a DC device is required. It can be made from the usual transformer unit, if it is to its secondary winding connect rectifier. Below is a diagram of a welding machine with a diode bridge.

Welding machine circuit with diode bridge

The rectifier is assembled on diodes D161 capable of withstanding 200a. They must be installed on radiators. Also, 2 condenser (C1 and C2) is required to equalize the pulsation of the current by 50 V and 1500 μF. This electroscheme also has a current regulator, the role of which is performed by the throttle L1. Welding cables (direct or reverse polarity) are connected to x5 and x4 contacts, depending on the thickness of the metal connected.

Inverter from computer power supply

The welding machine from the power supply of the computer is not possible. But use its body and some details, as well as the fan is quite real. So, if you make the inverter with your own hands, it can be easily accommodated in the BP housing from the computer. All transistors (IRG4PC50U) and diodes (CD2997A) must be installed on radiators without using pads. For cooling parts preferably use a powerful fan, such as THERMALTAKE A2016. Despite its small sizes (80 x 80 mm), the cooler is able to develop 4800 rpm. Also, the fan has a built-in revolver regulator. The latter are adjustable using a thermocouple that needs to be fixed on a radiator with installed diodes.

Tip! In the BP housing, it is recommended to drill a few additional holes for better ventilation and heat dissipation. Protection against overheating, installed on transistor radiators, is configured to trigger at 70-72 degrees.

Below is a circuit electrical diagram of the welding inverter (in a large resolution), which you can make the device placed in the BP housing.

The following photos show which components consisting of a homemade inverter welding machine, and as it looks after the assembly.

Welder from electric motor

To make a simple welding machine from the stator of the electric motor, it is necessary to choose a motor itself that meets certain requirements, namely, that its power is from 7 to 15 kW.

Tip! It is best to use the 2a series engine, because it will big window magnetic pipeline.

You can get the desired stator in places where the scrap metal is taken. As a rule, it will be cleaned from the wires and after a pair of blows a sledgehammer splits. But if the hull is made of aluminum, then to remove the magnetic circuit, it will be necessary to join the stator.

Preparation for work

Put the stator with a hole up and down under the detail of the bricks. Next, fold inside the firewood and burn them. After a pair of watches, the magnetic pipes are easily separated from the housing. If there are wires in the case, then they can also be removed from the groove after heat treatment. As a result, you will receive a magnetic circuit cleaned from unnecessary elements.

This blank should be fine oily And let her dry. To accelerate the process, the heat gun can be used. The impregnation of varnish is done so that after removing the screeds, the package does not occur.

When the disc will dry out completely using the Bulgarian, remove tiePlaced on it. If you do not remove the screed, they will perform the role of short-circuited turns and take the power of the transformer, as well as cause it with heating.

After cleaning the magnetic pipeline from unnecessary parts, it will be necessary to make two face lining (See Figure below).

The material for their manufacture can serve either cardboard or pressspan. You also need to make two sleeves from these materials. One will be inner, and the second is outdoor. Next, you need:

• install both end linings on the blank;
• then insert (dress) cylinders;
• all this design is wrapped with a migratory or glass bench;
• impust the resulting detail of varnish and dry.

Making a transformer

After the actions described above, a welding transformer can be made from the magnetic pipeline. For these purposes, a wire covered with tissue or glass emal isolation is needed. To wind the primary winding, the wire is required with a diameter of 2-2.5 mm. The secondary winding will require about 60 meters of copper tire (8 x 4 mm).

So calculations are made as follows.

1. On the core, the 20 turns of the wire having a diameter of no lower than 1.5 mm should be hosted, after which, it is necessary to submit a voltage on it 12 V.
2. Measure the current flowing in this winding. A value should be about 2 A. If it turned out a value of more required, the number of turns need to be increased if the value is less than 2a, then reduce.
3. Calculate the number of turns of the turns and divide it to 12. As a result, you will get a value that indicates how much turns are needed to 1 in voltage.

For primary winding Suitable conductor with a diameter of 2.36 mm, which is required to be folded. In principle, you can take any wire with a diameter of 1.5-2.5 mm. But before you need to calculate the cross section of the conductors in the twist. First you need to wind the primary winding (220 V), and then - secondary. Its wire must be isolated over the entire length.

If in the secondary winding, make a removal on the site where 13 V is obtained, and put the diode bridge, then this transformer can be used instead of a battery if you need to start a car. For welding, the voltage on the secondary winding should be within 60-70 V, which will allow the use of electrodes with a diameter of 3 to 5 mm.

If you laid both windings, and in this design there is free space, you can add 4 copper tires (40 x 5 mm). In this case, you will get a winding for spot welding, which will allow you to connect a sheet metal to 1.5 mm thick.

For manufacturing case Use metal is not recommended. It is better to make it from textolite or plastic. In places fastening the coil to the case, rubber gaskets should be paved to reduce vibration and better insulation from conductive materials.

Homemade dot welding

The finished apparatus for point welding has a fairly high price that does not justify its internal "filling". It works very simply, and make it his own will not be a lot of work.

To independently make a point welding machine, you will need one microwave transformer with a capacity of 700-800 W.From it you need to remove the secondary winding in the manner described above in the section where the manufacture of the welding machine from the microwave was considered.

The apparatus for point welding is made in the following way.

1. Make 2-3 turns inside the manitoprovod cable with a conductor diameter of at least 1 cm. It will be a secondary winding that allows you to get a current in 1000 A.
   
   
2. At the ends of the cable, it is recommended to install copper tips.
   
   
3. If you connect to the primary winding of 220 V, then on the secondary winding, we will receive a voltage 2 V with a current of about 800 A. this will be enough to melt a regular nail in a few seconds.
   
   

   

4. Followed by make a housing for the apparatus. A wooden board is well suited for the base, from which several elements should be made, as shown in the following figure. The dimensions of all parts may be arbitrary and depend on the dimensions of the transformer.
   
   

   

5. To give the housing a more aesthetic look, sharp corners can be removed using a manual milling with the edge cutting mill installed on it.
   
   

   

6. On one part of welding ticks need cut a small wedge. Thanks to him, the ticks will be able to rise above.
   
   

   

7. Cut on the back wall hole housing for switch and network wire.
   
   
8. When all the details are ready and grounded, they can be painted with black paint or to cover with varnish.
   
   
9. From an unnecessary microwave, you will need to disconnect the network cable and the limit switch. The metal door handle will also need.
   
   

   

10. If you have no foot and copper rod, as well as copper clamps, then the details must be purchased.
    
    
11. Copper wire cut 2 small rods that will perform the role of electrodes, and secure them in the clips.
    
    

    

12. Screw the switch to the rear wall of the body of the apparatus.
    
    
13. Screw to the base the rear wall and 2 racks, as shown in the following photos.
    
    

    

14. Secure the transformer based on the base.
    
    
15. Next, one network wire is connected to the primary winding of the transformer. The second network wire is connected to the first terminal of the switch. Then you need to attach the wire to the second terminal of the switch and connect it to another output of the primary. But on this wire should be taken and install in it microwave. It will execute the role of the welding button. These wires must be sufficient length so that it is enough to place the interrupter at the end of the ticks.
16. Secure the device cover on the racks and rear wall with the handle installed.
    
    
17. Secure the side walls of the case.
    
    
18. Now you can install welding ticks. First, drill on their ends along the hole in which the screws will be screwed.
    
    
19. Next, fasten the switch at the end.
    
    
20. Insert the pliers into the case, pre-putting between them for the alignment of the square bar. Drill in the ticks through the side walls of the hole and insert long nails in them, which will serve as axes.
    
    

    

21. At the ends of the ticks, secure the copper electrodes and align them so that the ends of the rods are opposite each other.
    
    

    

22. So that the upper electrode is raised automatically, screw the 2 screws and secure the gum on them, as shown in the following photos.
    
    

    

23. Turn on the unit, connect the electrodes and click the Start button. You must see the electrical discharge between the copper rods.
    
    
24. To check the unit, you can take metal washers and weld them.
    
    

    

In this case, the result was positive. Therefore, the creation of a point welding machine can be considered finished.

In view of the fact that in everyday builders often need to work with the metal, many use welding units. But not everyone may afford the acquisition of expensive equipment, which is why the question arises how to collect the welding machine with your own hands. The manufacturing process will differ depending on the type and design features of the welding device.

Types of welding machines

The modern market is filled with a rather large variety of welding machines, but not everything is advisable to collect with their own hands.

Depending on the working parameters of the devices distinguish such types of devices:

• on alternating current - outstanding alternating voltage from the power transformer directly to the welding electrodes;
• on constant current - outstanding constant voltage at the output of the welding transformer;
• three-phase - connected to three-phase network;
• inverter devices - outstanding pulse current to the workspace.

The first version of the welding unit is the easiest, for the second, you need to modify the classic transformer device with a rectifier block and a smoothing filter. Three-phase welding machines are used in industry, so we will not consider the manufacture of such devices for household needs. Inverter or pulse transformer is a rather complex device, so to collect a homemade inverter you must be able to read the schemes and have basic e-board assembly skills. Since the base for creating welding equipment is a lowering transformer, consider the procedure for manufacturing from the simplest to more complex.

On alternating current

According to this principle, classic welding machines work: the voltage from the primary winding 220 B is dropped to 50 - 60 V on the secondary and fed to the welding electrode with the workpiece.

Before making making, pick all the necessary items:

• Magnetic circuit - Capuls with a sheet thickness of 0.35 - 0.5mm are more profitable, since they provide the smallest losses in the gland of the welding machine. It is better to use the finished core from transformer steel, since the density of the fitting plates plays a fundamental role in the operation of the magnetic pipeline.
• Wire winding coils - The wire section is selected depending on the values \u200b\u200bflowing in them.
• Insulating materials - Basic requirement, both to leaf dielectrics and to native coating of wires - resistance to high temperatures. Otherwise, the insulation of the welding semi-automatic or transformer is melted and a short circuit will arise, which will cause a breakdown of the device.

The most advantageous option is the assembly of the unit from the factory transformer in which the magnetic circuit is also suitable, and the primary winding. But, if there is no suitable device at hand, you will have to make it yourself. With the principle of manufacturing, determining the section and other parameters of the self-made transformer, you can find in the relevant article :.

In this example, we consider the option of making a welding machine from the microwave power supply. It should be noted that transformer welding should have sufficient power, for our purposes the welding machine will be suitable for at least 4 - 5 kW. And since one microwave transformer has only 1 - 1.2 kW, we will use two transformers to create the device.

To do this, you will need to perform such a sequence of actions:

Fig. 2: Remove high voltage winding

leaving only low-voltage, in this case the winding of the primary coil is not needed to do, as you use the factory.

• Remove the coil chains on each transformer current shunts, this will allow you to increase the power of each winding.
  Fig. 3: Remove current shunts
• For the secondary coil, take a copper bus with a cross section of 10mm 2 and wrap it on a pre-made frame made of any girlfriend. The main thing is that the shape of the carcass repeat the gabarities of the core.
  Fig. 4: Wash the secondary winding on the frame
• Make a dielectric gasket for the primary winding, any non-combustible material is suitable. In length, it should be enough on both halves after connecting the magnetic pipeline.
  Fig. 5: Make dielectric gasket
• Place the power coil in the magnetic core. To fix both halves of the core, you can use glue or pull them together with any dielectric material.
  Fig. 6: Place the coil in the magnetic circuit
• Connect the plug output to the power cord, and the seconders to the welding cables.
  Fig. 7: Connect the power cord and cables

Set the holder and electrode with a diameter of 4 - 5mm to the cable. The diameter of the electrodes is selected depending on the force electric current In the secondary winding of the welding machine, in our example it is 140 - 200a. With other parameters of operation, the characteristics of the electrodes are changed respectively.

In the secondary winding it turned out 54 turns, for the possibility of adjusting the voltage value at the output of the device, make two taps from 40 and 47 turns. This will allow you to adjust the current in the secondary by reducing or increasing the number of turns. The same function can perform a resistor, but exclusively at a smaller side of the nominal.

On constant toke

Such a device differs from the previous one more stable characteristics. electric Dougie.Since it is not directly directly from the secondary winding of the transformer, and from the semiconductor converter with a smoothing element.

Fig. 8: Straightening concept for welding transformer

As you can see, you do not need to do the winding of the transformer for this, it is enough to finalize the scheme of the existing device. Due to which he can produce a more even seam, cooking stainless steel and cast iron. For the manufacture you will need four powerful diode or thyristor, about 200 and each, two capacitors with a capacity of 15,000 μF and choke. The diagram of connecting the smoothing device is shown in the figure below:

Fig. 9: Connection diagram smoothing device

The process of improving the electrical circuit consists of such steps:

In connection with the overheating of the transformer during operation, the diodes can quickly exit, so they need a forced heat removal.

To connect, it is better to use tinned clamps, as they will not lose the initial conductivity from large currents and constant vibration.

Fig. 12: Use tinned clamps

The thickness of the wire is selected in accordance with the operating current of the secondary winding.

When welding metals, such a device should always be controlled by heating not only the transformer, but also rectifier. And when the critical temperature is reached, making a pause for cooling the elements, otherwise the welding unit made by your own hands will quickly fail.

Inverter

It is a rather complicated device for novice radio amateurs. An equally complex process is a selection of necessary elements. The advantage of such a welding machine is significantly smaller dimensions and less power, in comparison with classic devices, the ability to implement, etc.

Fig. 14: Schematic diagram of the pulse block

In operation, such a scheme converts alternating voltage from the network to constant, then, with the help of a pulsed block, it gives a high amplitude current to the welding area. This achieves the relative savings of the power of the apparatus in relation to its performance.

Constructively inverter scheme of the welding machine includes such elements:

• diode rectifier with tank store, ballast resistor and smooth start system;
• driver-based management system and two transistors;
• power part from the control transistor and output transformer;
• output of diodes and chokes;
• cooler cooling system;
• system feedback By current to control the parameter at the output of the welding machine.

It will take for you yourself to wind the power transformer, the current transformer on the basis of the ferrite ring. For the bridge it is better to use finished assembly From high-speed semiconductor elements.

Unfortunately, most of the other elements are unlikely to be at hand in the garage or at your home, so they will have to be ordered or purchased in specialized stores. Because of what the assembly of the inverter unit will cost it no cheaper than the factory option, but taking into account the time spent, also more expensive. Therefore for inverter welding It is better to purchase a ready-made device with specified operating parameters.

Video instructions