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On the front, I flip up(on) the little switch on the left, this turns on the smaller LED, that gives me the Capacitors voltage. I wanted to box up the parts to provide a reasonably robust and neat finished product. Many thanks for shearing your knowlodge and experience. I also replaced the thin copper interconnectors between ultracapacitors with proper, clean busbars. I was looking at Roberts design and wondering what you think of a 10v 10F capacitor bank to be charged with a 9v battery (more for novelty than practicality)? Anyway, not having any more IRFP2907s on hand, I did another rebuild using IRFP4668 FETs, and upgraded to six instead of four devices in parallel, to give a bit more headroom. Thanks again for the comments and Thanks for taking a second look! Reply Everything seems to go together well. I Applied power and turn it on. Then, the energy is rapidly released into the parts within milliseconds. Am I correct ??? Cheers! Any though? 2 years ago. DIY Capacitive Discharge Battery Spot Welder - ZEVA The PCB's are held in place with M4 nuts ad bolts. These resistors limit the current used to turn on the gates on each of the 2 MOSFET's. Having said that, working under an LED illuminated desk magnifying glass is a great help! Here, for example, I don't know how the thyristor is driven. Machines are available 'off the shelf' specifically designed to do this. The ProTip is how to make a simple Battery Tab welder from an Audio Capacitor(.6F and up) This has also ended up to be my favourite one of the 7. Comporents , wiring and adjustments used: 6 Maxwel Ultra Capacitors 350 farad 2.7 volts in psrallel. Rather than designing the circuit I just built it! If you look at the Schematic/Pictorial I created. This welder has proven to give me the best welds to date, next to my 12v Battery Tab welder. If a MOSFET were to fail it would be a mini nightmare to find out which one had failed! 3)Finally, I fitted an on/off push button switch. Of course, in hobby CD welders we're usually abusing the components a bit so I guess having stuff blow up is more common! The SCR will drop a lot the voltage that means you will need higher voltage capacitor which is expensive. Here are the Parts I used on this build. P-channel devices usually have higher on-resistance. This was also a good time to test the TP4056 I will be using to charge this up. Hundred Dollar Capacitive Discharge Welder | Hackaday Thanks for the great write up on your CD welder. I added the Capacitor and the wiring as it specified in my schematics and it fit where I figured it would. Since my first MOT welder, I've been wanting to do one of these and I am happy I did! I don't normally prep the components until assembly, but this one, I wanted to use Screw Terminal Barrier Connectors on all connections. After I measure and center the area I need to drill. Interesting that you got better results with just 0.2F capacitance! A nice production unit is about $6-12K with the weld head. except my China made 2.5F super cap was unable to output high current. I notice that you didn't include pulse widths that gave optimum welds. 1) The positive link - to be connected to a bench top power supply. arran on 26th Aug 2013 I think the capacitor will charge quick enough that the virtual short will only be a couple of seconds, I would try not to discharge it completely so for multiple wields the cap will have a good initial resistance for subsequent charges (in theory) I'll be using 200A thyristor and quarter inch copper as the electrodes, my main concern is that the 4x 2.7v caps will have their legs blown off/melted on discharging. I have read that the spot weld itself needs about 200 joules - not sure if that's per spot or for a pair, but at any rate it's clear that the equipment is soaking up most of the energy rather than delivering it to the weld. Thanks for your comments, and I do value your feedback. The inductance of the shorting bar caused the capacitors to be reverse charged almost to the smae voltage. Basically, unfortunately I can't see a way to use ultracaps with an SCR switch. Capacitive discharge spot welder | Hackaday.io I seems that the currents obtained is not hot enough The signs on the strips (sunston) are hardly seen. I'm an old Roughneck from Texas/New Mexico and old Millwork Manufacturer Manager/Carpenter from Seattle. A box for it might be nice, but the naked electronics has it's own charm too. there's another in series that will still be able to turn off, and that that can often prevent what may well otherwise (and here i'm particularly fuzzy) have been the death of all the mosfets. To me, it was not quite a pictorial, and Not quite a schematic.Thanks for the comment. Ian Hooper on 23rd Aug 2013 Hi Arran, not sure about the 9V battery idea.. there's a fair chance of damaging the battery if it's repeatedly seeing a virtual short circuit while charging up the capacitors! Here I show the connection to the capacitor bank from the benchtoppower supply. At 3amps, this should be about right for 2F. I plan on getting a bigger one in the future. meguit@rist on 10th Jul 2013 hello Ian, Thanks for yr prompt reply. ok, i can not find any real understandable info so someone please help? Capacitive discharge welders, otherwise known as capacitor discharge spot welders or CD welders, aren't new technology, but they do have many advantages. From memory I was using much longer pulse times than 10ms with my original prototype. Ian Hooper on 23rd Jun 2013 Hi Issam, IRF3205 looks OK but as with Portablepowerman (above), you'll probably need to use more TO220s in parallel compared with TO247s, because they are a smaller package. After the dry-Fit, I made sure to measure with a ruler where each part would fit. In parallel all six would only give you 0.28F which is a quarter of what most people use when welding at 12V. DIY Capacitive Discharge Welder - Build Video swipemagnetron 2.59K subscribers Subscribe 75K views 7 years ago Upgrading the capacitors and boost converter on my battery tab welder for. NB: In hindsight I would prefer these to be pluggable rather than permanently soldered. Everything, but the (2F to .6F), of the Capacitor, tested right. I roughly knew what I wanted it to do and just set about implementing each feature as I went along. The total cost of the bank is about $120. The nominal capacitance is only the initial mininimum, so the voltages across the capacitors will typically vary, leading to the possibility that one reaches its limit while others are still charging to bring the total voltage to the level intended. Fixing/upgrading it was quite a learning experienced, speckled with several other blown MOSFETs. I don't have a bill of materials for the build because it was just a one-off. I normally answer back pretty quick. Also, the MOSFETs were all triggered by the same gate driver. Here's the datasheet. A little dap of Hot glue on everything and it shouldn't move one bit. please a detailed explaination? I believe I can make a reasonable pack from old cells removed from old laptops or similar devices which use the common 18650 cell size. Please let me know if you have any questions. Great DIY Buid project, perfect thanks!I see some improvments to be made on circuitry though. Right is a labelled diagram showing the layout and control board on top (click to view larger). Separate power supplies for capacitors and logic circuit must be used because the ultracaps charge very slowly (about a minute to reach welding voltage), and the AVRs don't particularly like such a slow ramp up of supply voltage. Otherwise check out Ebay surplus hockey-puck SCR and stay easily within ratings. Then add the 3 capacitors. This was a really Fun Build and the welds it produces are Great. The reason I chose to make a low voltage welder, was to show I could. In a proper manufacturing situation, this is usually done with outrageously expensive welders. Three? I am thinking also to design a machine for my own use and I was looking around what is available. It seemed like a good idea, but without realising the consequence at the time, I had greatly reduced the overall resistance of the weld circuit, which greatly increased weld current, and blew the new MOSFETs! Thanks! I'll gather all the required components, etch the board & test out. meguit@rist on 10th Jul 2013 Great Project! Adjustable pulse time with potensiometer 25-250 ms. 8 IRFB7430 in parallel mount on their respective heat sinks The whole thing wired on thick wires especially the out put starting from the negative (-) terminal of the capacitor bank to a common (unique) ground - negave bar, then to the sources of the 8 mosfets, then the 8 exiting drains in parallel from mosfets to the negative black prod. I'd be interested to hear from anyone who knows of a good source of nickel strip in Australia. I wasn't to worry about cleaning everything up. I would have to wait a little longer inbetween welds, or it may overheat. I will add you here on Instructables! Ian Hooper on 4th Mar 2014 Yeah I got my last bits from Sunstone.. and I can only agree that postage to Aus is very expensive :(, kyriakos on 4th May 2014 Dear Ian I finished my welder but the weldings are not strong. 7) 2 Diodes on the 12V input to provide input polarity protection. 1 year ago, I have been trying to find solution but could not. The hardest part to duplicate would probably be the power stage as you probably won't have suitable PCBs on hand, but can just solder large wires straight to the legs of the MOSFETs. They both have some really great content on Capacitor welders. And the - Terminal of the capacitors bank conneting their (drain) pinds to the negative electrode of the welder. meguit@rist on 30th Jul 2013 Hello Ian, I just bought 27x27k.uf 35v cap today & tested 8 cap in parallel. I made my electrodes from aluminum bar - the diameter is about 10mm. This page gets a fair few visitors so it has been on my "To Do" list to design a better CD spot welder from all that I've learned since - perhaps something that could be offered as an inexpensive kit containing PCBs and busbars to make it easier for others to try building..) Anyway good luck with your build! Thanks can you send it to my email address xxxxxx@libero.it. Some commercial spod machine have 2F or 4F and have two pulses of around 3.5ms. Digikey has them for about $5ea, so quite a bit cheaper than the ultracapacitor route. What is your opinion? Easiest option may be to build or buy a 1 Farad capacitor as per their designs! They use an SCR switch and you use MOSFETs. With a quantity of K2 26650EV cells sitting in my workshop, orphans from a cancelled project, it seemed like a good idea to build myself a CD welder such that I could assembly these cells into packs suitable for use in my various electric vehicle projects. I just happened to have 4 x 48Ohm resistors on hand soIused them 2 in parallel and 2 in series. Musings: I think if I built another spot welder, I'd go with 1 Farad of normal capacitors instead of ultracapacitors. on Step 2. I have found when I write one up, 9 out of 10 times, I end up revising it as I go along. It is possible to fix the battery tab to the battery using traditional soldering techniques. But may be an interesting experiment. Thanks in advance. This driver chip is easily available as a SMD component. I imagine a shower of sparks, and/or things getting burned. I actually can't get IXDD414s anymore in my country (Australia) either! All the high power wiring is 8AWG, which has a resistance of around 2mohm per metre. It's good to make sure, that nothing will be in the way of any other part or wiring.With this build, I have noticed that the Capacitor is a little to big for the case, and I may need to place the bigger part of the SCR on the outside of the case. As he notes in his writeup, the properties of copper which are most enticing, such. When cutting these holes, I like to use a StepBit. U8GLIB_ST7920_128X64_1X u8g(13, 11, 12); // SPI Com: SCK = en = 15, MOSI = rw = 16, CS = di = 17. Please excuse me for my weakness in English. And higher current is harder to control/switch, of course. My completed Ultra Capacitor discharge spot welder still gives disapointing poor results, low or no penetration. The APC UPS case, I found at the local goodwill for around 5$ completed and working with an actually good 12V sealed lead acid battery 7.4Ah. You could try say 8-10x 3205s in parallel, also start testing at a lower voltage - say as low as 5V, then increase in 1V increments until you get nice welds (hopefully without blowing FETs). I originally wanted to get an SCR with a heavy flexible cathode cable but those were nearly 3X the price. I am in no way shape an expert at filming and these were done in the begging of my journey. John on 24th Mar 2013 Hi! So Placed 2 together and used hot glue to hold in place, Than I soldered the wire and twisted them together for barrier blocks later. This is the technique often used for the welding of battery tabs. With the plan on doing the caparison Video as soon as I finish my 7th and 8th welder(both low powered). After some search on Google I found that Tungsten tips was able to welds copper to copper. Note that TO220 packages aren't as beefy as TO247s (smaller package, smaller legs etc) so you'd probably need half again as many for the same power handling. The person I got the idea for the old APC UPS case, used a Hockey Puck Style for his and he gets pretty close to the same results. DIY Battery Tab Welder - Capacitive Discharge Type - RC Groups I used 4 47Ohm 5 Watt resistors. Thanks in advance. If I need a higher voltage on the Buck Converter, I drilled 2 small holes in the top of the case, where I could adjust as needed. I like your idea of connecting the SCR (what you youngsters call thyristor) directly to that low voltage capacitor terminal to keep the series resistance low. Well done you! November 6, 2011 Hackaday reader [David] was looking for a cheap and easy way to spot weld copper tabs together. Light on the back seems to be working when I power the unit on. Using materials I already had around the garage I mounted the PCB assembly inside the case. NB you will need to download and use the U8glib library which is used for the LCD display! When I contacted the seller, they did not act one bit surprised, but made the sell fair and offer me a rebate. Now, if I can keep my self from trying to design dual pulse circuitry I might actually be able to build some battery packsCheck out some welds here:https://www.youtube.com/watch?v=u6-HpR7Wfr8Check out welder version 1 here:https://www.youtube.com/watch?v=TNclCrfsgJQWord of the day: \"Allright\"BE CAREFULTime Code Index:Old vs New Voltage Boosterhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=0m52sPower Discussion Spreadsheethttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=1m42sCapacitor Mock Uphttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=2m34sCopper Cuttinghttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=3m0sCapacitor Configurationhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=3m49sCharging System Mock Up http://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=5m26sEbay Booster and Buck Converterhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=5m48sWiring Voltage Boosterhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=7m55sBoost to Buck Wiringhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=8m40sCharging System Wired Uphttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=9m25sCharge/Discharge Test with old Capacitorhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=11m17sCapacitor Charging and Electrode Connectionshttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=13m16sFinal Mock Uphttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=14m31sSilicon Controlled Rectifier (Switch) Gate Triggeringhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=15m35sElectrodeshttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=16m7s18650 Cells for Gate Triggeringhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=17m17sThree Wire Volt Meterhttp://www.youtube.com/watch?v=OtCiorlYP1U\u0026t=18m40sTest! Ensure they are placed the right way around with the metal tabs facing the capacitors. Nickel strip can be purchased from Powerstream or Sunstone Engineering. If parameters for each are 1500F and 2.7V. It also avoids (minimises) switching losses in the FETs, and (now) I also believe it avoids the need for any freewheel diodes. Sergioty on 6th Jul 2014 kyriacos, looking at your design, it looks like your are not getting enough current due the internal resistance of the supercapacitor.

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