Powerful DIY Spot Welder Tutorial for 18650 Batteries | DIY Homemade Spot Welder
Introduction:
Welcome back, DIY enthusiasts! Today, we have
an exciting project in store for you – building your very own powerful spot
welder tailored specifically for 18650 batteries. Whether you're a hobbyist or
a tinkerer, this DIY homemade spot welder tutorial will guide you through the
step-by-step process of creating a versatile and efficient tool that's perfect
for your battery-related projects.
Why Build a Spot Welder for 18650 Batteries?
Spot welding is
essential for creating strong, reliable connections between battery cells, and
18650 batteries are a popular choice for various applications, from power
electronics to DIY power banks. Building your spot welder not only saves you
money but also gives you complete control over its power, precision, and
design.
Materials You'll Need:
Before diving into the tutorial,
gather these materials:
1. Transformer
2. Copper welding cables
3. Welding electrodes
4. Microcontroller (Arduino or similar)
5. MOSFET module
6. Current shunt
7. LCD screen (optional)
8. Enclosure for the spot welder
9. 3D-printed or laser-cut parts (for electrode holder and
pressure mechanism)
Insulated tools
Safety gear (gloves, safety glasses, apron)
Step-by-Step Tutorial:
Step 1: Design and Prepare the Enclosure
Plan the layout of your spot welder's components inside the
enclosure. Ensure adequate spacing for airflow and safety.
3D-print or laser-cut the necessary parts for holding the
electrodes and the pressure mechanism.
Step 2: Wiring and Assembling
Connect the primary and secondary windings of the
transformer to ensure the desired voltage and current output.
Attach the copper welding cables to the transformer's
secondary winding and the welding electrodes to the cables.
Connect the MOSFET module to the microcontroller, and wire
the current shunt and LCD screen if you're using them.
Step 3: Microcontroller Programming
Write or upload a suitable program to your microcontroller
(Arduino, for example). This program should control the timing and duration of
the welding pulses based on user input.
Implement safety features, such as a cool-down period to
prevent overheating and emergency stop functionality.
Step 4: Testing and Calibration
Before working on actual batteries, perform tests using
scrap metal pieces to calibrate the spot welder's settings and ensure proper
functionality.
Adjust the welding parameters, such as pulse duration and
power, to achieve consistent and secure welds.
Step 5: Safety Precautions
Always wear safety gear, including gloves and safety
glasses, when operating the spot welder.
Work in a well-ventilated area to avoid inhaling fumes
generated during welding.
Conclusion: Congratulations! You've just completed the DIY
spot welder tutorial tailored for 18650 batteries. This powerful and versatile
tool opens up a world of possibilities for your DIY battery projects. From
assembling power banks to building custom battery packs, you now have the means
to create secure and efficient connections. Remember to prioritize safety and
perform thorough testing before working on actual battery cells. Happy welding!
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Disclaimer: This tutorial is for educational purposes only. Building and operating a spot welder involves working with electricity and potentially hazardous equipment. Follow safety guidelines, take precautions, and ensure proper knowledge of electrical systems before attempting this project. The author and publisher are not liable for any accidents or injuries resulting from the use or misuse of the information provided in this tutorial.
18650 / 26650 DIY Portable 12V Battery Storage Spot Welding Machine PCB Circuit Board Welding Equipment Spot Welders Pen
The circuit board of this spot welder can be used for
welding 18650/26650/32650 lithium batteries. Advantages: portable, stable,
reliable, and durable. Low cost, If you have a car starter battery or a high-power
battery pack, you can connect it and use it! Save production costs!
Users need to bring their own 12V battery for power supply,
the welding current is about 90A~130A, and it is easy to weld the common
0.1mm~0.12mm nickel-plated sheet. Please make sure that your battery can have a
current greater than 90A, otherwise you will not be able to weld!
Power supply voltage: 12V-15V
Working current: 90-150A (discharge below 90A, it will not
work.)
A battery with a large discharge current will directly
affect the welding effect. The following batteries are recommended:
20-45ah Lead-acid batteries with good performance and small
internal resistance (internal resistance less than 10 milliohms, discharge
current greater than 90A), such as a new car starter battery!
3.5-5.5ah 3S model airplane lithium battery pack around 45C
30-35ah capacity 18650 battery pack
Power requirements:
Spot welding is welded by the principle of rapid local
heating and cooling by high current,
Need sufficient current supply, generally 0.1-0.15 nickel-plated sheet welding current, about 90-150A, so the working power of the circuit
board must be greater than or equal to 150A.
The following battery packs can be used as working power
12V car starting power supply, 3S high-rate battery pack for
model airplane, three-string high-rate lithium battery pack,
Hitachi 40900 3-string battery pack, lead-acid battery with
good performance above 12V 20A.
Calculation formula: capacity X discharge rate = load capacity
Take 4000ma aeromodelling battery as an example, the
discharge rate is 45C (4AX45C = 180A)
Instructions for use:
Function buttons: 1, used to switch the machine, 2 used to
switch gears!
When the power is turned on, the default is the first gear.
Press the button for 2 seconds to release
The gear is increased by one gear, and the buzzer sounds and
the LED flashes corresponding to the number of gears.
For example: in the 3rd gear, the buzzer sounds three times, and the LED flashes 3 times, a total of 5 gears. The spot welding intensity is
gradually strengthened from the 1st gear to the 5th gear
The 5th gear is the strongest!
After the 5th gear, press and hold the button again. It will
power off. In the off state, press and hold the button to power on, and the gear
will return to the first gear.
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