Semi-automatic welding machine for household purposes with their own hands: inverter circuit, preparation, drafting
Man, who has some knowledge and experience in the field of electronics, is quite capable of coping with such a task, as making a semiautomatic welding machine with your own hands or repairing it. It is enough to prepare a certain set of elements and devices. If you compare inverter semiautomatic devices with similar welding equipment, then the first stand out, first of all, lighter weight, due to which there are no special difficulties in working with them. In addition, you do not have to resort to special devices, to move them to another location.
Device of self-made welding semiautomatic device
If we briefly describe the scheme of operation of the inverter device, then its essence is as follows: a pulsating voltage occurs after the rectifier is applied to the rectifier, due to which the smoothing of the filter is provided, the result is a constant current at the output. Transistors allow you to create a constant AC, having a frequency of from 20 Hz and above.
Due to the voltage drop, its purpose may be in the range 70-90 V, the current demonstrated by the current can reach the mark 200 A.
Such features allow a homemade semi-automatic welding machine to demonstrate similar qualities, as most of this equipment.
However, repairing these devices can be difficult, given the presence in the system of complex circuits.
With that in mind, that the inverter operates by changing the AC current instead of using an EMF frequency converter, this provides the device with small dimensions and light weight.
However, to repair such equipment, the owner must have some knowledge of electrical engineering.
Semi-automatic device
According to the scheme, weight of conventional electric welding equipment, which provides current 160 A, is not more 19 kg. Inverter on the background, having similar technical characteristics, weigh in 2 times less, and the current shown to them can reach 250 A.
In this case, each of these devices for welding can be made with their own hands. According to the scheme in the equipment of the inverter welding semiautomatic device not only the power supply is presented, but also a number of other mandatory elements:
- burner;
- device, which provides wire supply;
- flexible hose, through which the wire and gas under pressure.
Features of semiautomatic welding machine manufacturing
The manufacture of inverter semi-automatic machines is quite difficult to implement, because the owner needs to create a wire feeder yourself.
Materials
If the owner is determined to achieve his, then he in addition to the scheme must prepare tools and materials, the full list of which includes the following:
- transformer, providing current from 150 A;
- mechanism, which provides wire supply;
- flexible sleeve, by means of which gas is supplied;
- coil with wire;
- control device.
The feed mechanism is a very important component of welding equipment, because it is thanks to him that the wire will be supplied to the welding zone by means of a hose.
Of particular note is the speed of the wire for welding, which must come at the same pace, as the process of melting consumables. It is the speed of the wire that affects what, how well the seam will be created. For this reason, it is advisable to include such a device in the welding system, as a speed regulator. Thanks to it the ability to perform welding from any wire, regardless of material and diameter.
Most often, a wire with a diameter of is used to create a weld 0,8 to 1,6 mm. It should be placed on the reel, after which refueling of the inverter for welding is already carried out. It is desirable to do so, so that the electrode wire enters the burner in automatic mode. This can speed up the welding process.
Instrument, which controls the operation of the inverter semiautomatic device, equipped with a regulator to stabilize the current. An electric chip is provided in the system to provide the required amount of current, represented by a microcontroller, operating in the mode of the pulse-width modulator. An important parameter is the fill factor, which affects the voltage, which is created on the plates of the capacitor. And he at the same time determines the electric force of the welding arc.
Features of transformer preparation
To get an idea of the peculiarities of the preparation of the transformer for the manufacture of homemade welding semiautomatic devices, it is important to consider the following point: on the execution this device does not differ from that, which is used in a microwave oven.
There are two reels in the design of this device, contain insulated copper wire. They act as primary and secondary windings. This product will play a key role in creating a homemade inverter.
Due to the mismatch of the number of turns of the wire, the first current flows to the primary coil, and then due to the effect of induction in the secondary coil there is a decrease in voltage, which leads to an increase in current. If it was decided to create an inverter welding semiautomatic device based on a transformer, which was used in a microwave oven, then you have to make some changes to its design.
This need is due to the fact, the voltage emitted by this device exceeds the required value, at which normal work of the welding machine will be provided. For this reason, the main task will be to increase the current and simultaneously reduce the voltage characteristic. One important point should be mentioned: increasing the current can lead to ignition of the electrode and damage to the metal workpiece, if the current is too weak, then during welding it will be impossible to provide a seam of sufficient reliability.
At this stage, it is important to perform the correct calculations, otherwise created semi-automatic welding machine will soon require repair. If we return to the necessary changes in the design of the system, then this means the processing of the secondary winding: you need to remove the old winding first, carefully wind a new one on it, the quality of which should be used wire with protection on the basis of enamel. All turns must be placed very tightly, repairs should be carried out as carefully as possible, otherwise there is a risk of damaging the primary winding.
On such parameters, both the thickness of the wire and the number of turns can not be stopped, since their choice will be determined by the type of transformer being repaired. However, to calculate the optimal performance you can use an online calculator. After creating the required number of turns of the winding should be protected with a current-insulating substance.
Housing selection, coil alignment and installation
Before you start self-assembly of the semiautomatic welding machine, it is necessary to solve a question with a suitable variant of the case. Alternatively, you can consider a box, which has the required dimensions, of sheet metal or plastic. The selected building will be the place, where the transformers will be installed, then you need to connect their primary and secondary coils.
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The connection of the primary windings is performed in parallel, and secondary - in sequence. The inverter semiautomatic device made with the similar case will be able to accept current in size 60 A, providing the output voltage 40 St.. Thanks to such working characteristics it is possible to create comfortable conditions for performance of welding of the house.
- The main task of the cooling system of the self-made welding semiautomatic device is protection against overheating of the inverter in the course of work. To solve this problem, you must follow the following layouts of devices: first you need to install fans in the case, for which plots are allocated on both its sides, located opposite the electricity converters.
- The problem with fans is solved by buying them in a store or borrowing from an old computer system unit. Make sure before installing, that they are able to provide air flow to the hood.
For efficient removal of heated and cold air supply should be provided in the body of the semi-automatic machine with his own hands a few dozen through holes. You can buy welding cable holders in a specialty store. The self-made welding semiautomatic device cannot be created without a gas cylinder: it can also be purchased in a store or borrowed from an old fire extinguisher. When the investor is connected to the network, the microcontroller will immediately start working and adjust the optimal characteristics for welding. In the presence of voltage on the cable, not 100, it is possible to draw a conclusion about malfunction of the device. In this case, you need to diagnose and eliminate the cause.
Electrode wire feed rate device
Although manufacturers position welding machines as very reliable devices, quite often they fail due to the wire feed regulator, which forces the owner to often repair it. If you have problems with this item, then in the future it may negatively affect the work of the semi-automatic welding machine.
With a positive result, the owner needs to spend more time on welding and replace the electronic wire. Considering, that at the moment of giving of a nozzle of the welding unit the wire is fixed, to repair the owner will have to remove the nozzle and clean the contact area.
If there are problems with the operation of the wire feed control regulator, then this allows us to conclude about the suboptimal flow rate of the welding wire.
Failure of the control regulator can be caused also by malfunctions in its mechanical part. The scheme used in it provides a pressure roller, which is equipped with a regulator of a level of a clamp of a wire, as well as a wire feed roller. The latter is characterized by the presence of two recesses, from which the welding wire with a diameter to 1 mm
After the regulator is the solenoid, whose main function is to control gas supply. Considering, that the regulator is a fairly massive element, and its fastening to the panel of the device is provided only by some bolts, will be considered correct, that the feed regulator does not have a reliable support. This feature can lead to skew in the design of the semiautomatic device, which can also cause it to fail.
Conclusion
Despite the fact that a large selection of different welding units is available for sale, each owner can save money on its purchase, if you decide to make such equipment with your own hands. This idea is easy to implement for that reason, that materials and tools can be used for it, which are not difficult to find. At the same time do not be afraid of that, that the self-made welding unit will fail quickly. The main thing is to follow the scheme of creating such equipment, and then its work will take place with optimal performance, which will allow you to create reliable welded joints.
