How to make modern welding machines do it yourself

How to make modern welding machines with your own hands? Very often, the real owner in the house is required to make any repairs, such as metal fencing, flower stands made of metal, metal structures in the garage, water supply. There are many things that require welding and welding apparatus to repair.

Electrical circuit of the inverter welding machine

Electrical circuit inverter welding machine.

Now there is a lot of various equipment for these purposes, but the question arises: is it possible to assemble welding machines with your own hands? This is not very difficult, but will require some knowledge of electricity and skills to work with similar electrical appliances. In addition, it is inexpensive. And on the savings you can buy another useful tool.

Tools and materials

Tools that will be needed to assemble the welding machine:

  • clippers;
  • soldering iron;
  • drill;
  • file;
  • hammer;
  • set of screwdrivers;
  • passatizhi.

From the materials that will be needed for assembly, we get the following list:

Welding machine transformer

For the welding machine, you can use a transformer from an old microwave oven.

  • wire with enamel insulation D = 8 mm;
  • copper tube D = 14 mm and a length of 4 cm;
  • brass screws and nuts;
  • current insulating varnish;
  • PCB plate 5x3 cm and 4 mm thick;
  • 7 mm and 12 mm drills;
  • M6 bolts in the amount of 10-12 pcs .;
  • washers for bolts in the amount of 20-24 pieces;
  • nuts under the same bolts in the amount of 20-24 pieces;
  • durable plastic container for the case;
  • exhaust fans from the computer power supply - 2-3 pcs .;
  • thick stranded wire in the amount of 4 pieces with a length of 50 cm;
  • a pipe with a diameter of 3.5 cm and a length of 25 cm;
  • rubber hose or nylon sleeve;
  • transformer with an old microwave oven.

The welding machine is connected from a current with a voltage of 220 V or 380 V, electrodes with a diameter of 3 or 4 mm are used. These characteristics of the equipment allow the processing of steel products with a thickness of 1-25 mm.

In order to assemble such a welding machine yourself, with your own hands, first of all, a transformer is necessary - the heart of the device.

Back to table of contents

Transformer assembly

Transformer circuit with primary and secondary winding

The scheme of the transformer with the primary and secondary winding.

It should have three phases, the function of voltage reduction, and power - 1-2 kW. Also, the transformer must have two different coils on which a copper enameled wire is wound. One is called primary, and electricity is connected to it, and the other is secondary. The number of turns they have is different, and they are wound on an iron core.

For these purposes, perfect transformer with an old microwave oven. The only disadvantage of this transformer is that the second coil has too high a voltage. Therefore, you need to wind off a few turns.

When the voltage becomes less, the current will increase. The fact is that if the current strength is small, the welding will go poorly. And if, on the contrary, the current strength is very large, the electrodes will fail and the metal will deteriorate.

Then the secondary winding is rewound, it must be very dense, the wire must have enamel insulation and a diameter of 8 mm. This cable is able to withstand high currents.

To say in advance how many turns needed, it is impossible. These parameters are calculated individually for each welding machine.

After every thirty turns, you need to make taps, all of them should be about ten pieces. Branches must be numbered, otherwise you can confuse. Terminals are made for these conclusions from a copper tube with a diameter of 14 mm and a length of 4 cm.

To make a pipe, you need to flatten it with a hammer and drill holes with a diameter of 12 mm. The stripped and tinned wire is inserted on the other side of the tube and crimped. Standard transformer screws and nuts must be replaced with copper ones. With their help, fixed terminals from the secondary winding. Next, the winding is covered with a special current-insulating varnish.

To connect the primary winding will need a plate of PCB 5x3 cm and 4 mm thick. In it you need to drill holes from 10 to 12 pieces with a diameter of 7 mm. Then they insert the bolts M6, each of which has two washers and nuts.

Back to table of contents

Welding machine assembly

Metal case of the welding machine

The factory-made welding machine body can be metallic.

Now you can proceed to the next stage of equipment assembly - the welding machine body, since all the spare parts need to be fixed somewhere. The body can be made of durable plastic containers. Attach the transformers one after another, such a scheme will lead to a decrease in the voltage so that the output current will be equal to 50 amps.

To check, you can measure the current strength with a special device. After installing the transformers on their seats begin to connect the windings. The primary windings are interconnected in a parallel way, and the secondary - in series. As a result of this work, the output voltage is approximately 38 volts, and the current strength under load is no more than 60 amperes.

What else should you think while collecting modern welding machines with your own hands? Of course, about the cooling system, otherwise the device may catch fire from overheating.

For this, holes are cut out in the plastic case, several exhaust fans are fixed, 2-3 will suffice. They need small, can even come up from the power supply of the computer. It is also necessary to make holes at the bottom of the tank capacity so that there is a thrust and air flows through the internal cavity of the housing.

Back to table of contents

Welding Electrodes

Stranded copper wire

For the manufacture of electrodes need stranded copper wire.

Further, electrodes are necessary for the welding machine to work. In order to make them, you will need a thick stranded wire in the amount of four pieces with a length of 50 cm.

One electrode can be made similar to forks or pliers, it may in the future help to hold certain objects while welding. The second electrode is convenient to make like a soldering iron. To do this, you can use the handle of the soldering iron, fix it on the wire and insert a graphite rod from the battery.

Electrodes are ready, and now they can be connected to the welding machine with the help of holders. For their manufacture it is necessary to take a pipe with a diameter of 3.5 cm and a length of 25 cm. With a hacksaw, recesses are cut from both sides at a distance of 4 cm from the edges with a depth of 1/2 the diameter of the pipe.

Through the cuts with steel wire they press the electrodes to the holder. A hole with a diameter of 8 mm is drilled on the other side, and a cable is attached to the holder, the same as on the secondary winding. A rubber hose or a capron sleeve is worn on top. The welding machine is connected to the network using a knife switch with wires with a cross section of 2 to 4 mm.

This is how welding machines are made by hand. And most importantly, what you should always remember, the rules of operation of the welding machine.

Back to table of contents

Rules of operation of the welding machine

First of all, such a device is not designed for long welding, only up to 10 electrodes. Then, in order to avoid overheating, the apparatus must be cooled down. Also, when carrying out unsafe welding works, it is necessary to use a special protective mask against burns, a fiber shield, mittens and work clothes. We also need a protective headdress.

After all the work, the device is turned off, and the wires are carefully unwound so as not to damage the terminals. In addition, it is necessary to ensure the welding machine storage in a dry room, as it is afraid of moisture.

Add a comment