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Spot welder / spotwelder choosing the right one
#11
Thank you guys for a help.

I'm surprise that even 28Ah AGM could deliver enough current to spot weld weld, but when you think about it, when dropping the wrench on even 7Ah battery sparks are flying, and somtimes even grab and weld to electrodes.

@Mikethezipper
"The only thing I don't like about it is that there really isn't that much info I could find about the malectrics one - on what settings to use etc"

It's because weleder, just allows current to pass throug the electrodes. Simple AF.
Constant are the limitation of welder (resistance on cables and max allowed current that can mosfets pass thorugh)all the wariables are depends on the user, so they need to adapt basing on three wariables and learn on own mistakes.
1. Time (ms)
2. Source of supply (battery/transformer) Current that strictly depends on Voltage, and so on..
3. Material that we use to connect
Packs build:
7S1P 60Ah ~1.5kW SAMSUNG SDI prismatic cells - I'm looking for more info about them / PV if you know more Huh
7S84P 240Ah ~6.2kW from 588x cells LG MG1 2850mAh
Inverter - 3kW AIMS  pure sine
Solar - considering addding 220W with MPPT Make Sky Blue 30A
Set up for mobile gastronomy 2kW cooling compressor + 500W appliancies
Spot Welder - Mactronic V3.
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#12
I find spot welders to be quite expensive so I think I'll design my own at a point.
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#13
Thank you all guys.
I decided to buy Malectrics spot welder and pair it with 6S1P or 2P 350F maxwell supercaps (with proper BMS Vmax 13,5V max and 840A short current, can be doubled if needed - but welder may not hold it)
Packs build:
7S1P 60Ah ~1.5kW SAMSUNG SDI prismatic cells - I'm looking for more info about them / PV if you know more Huh
7S84P 240Ah ~6.2kW from 588x cells LG MG1 2850mAh
Inverter - 3kW AIMS  pure sine
Solar - considering addding 220W with MPPT Make Sky Blue 30A
Set up for mobile gastronomy 2kW cooling compressor + 500W appliancies
Spot Welder - Mactronic V3.
Reply
#14
(03-05-2019, 09:26 AM)Issac Wrote: Thank you all guys.
I decided to buy Malectrics spot welder and pair it with 6S1P or 2P 350F maxwell supercaps (with proper BMS Vmax 13,5V max and 840A short current, can be doubled if needed - but welder may not hold it)

Congrats on your purchase of the Maletrics unit; looking forward to reading your user experience. I'm still torn between the Maletrics and KWeld.

In the meantime, could you please share the full components purchase details of your Maxwell supercaps build including the BMS/balancing boards? I've been wanting to go that route but have not been able to locate how to build such a pack for the $80 (or thereabout) that you stated earlier yours cost you. Thanks.

........
P34c3
.....
...
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#15
@duwdu

Working very well, but I do not have comparision to k-weld.
As I remember I choose malectrics because they have confirmed working history with supercaps.

But I switched to lead-acid car battery, because caps didnt work. 
I think because they were old (2007 manufakture date ~10 years lifespan), even when charged to max they cannot give proper current, and welds were very weak. (with 6S2P configuration of 350F 2.5V charged to 13.5V it sucs..)

BMS board i bought on ebay, from seller that no longer exists. I did connect it later with extra copper wires blobed with solder, no change. 

I found on ali the same one:
https://pl.aliexpress.com/item/32813057355.html
Packs build:
7S1P 60Ah ~1.5kW SAMSUNG SDI prismatic cells - I'm looking for more info about them / PV if you know more Huh
7S84P 240Ah ~6.2kW from 588x cells LG MG1 2850mAh
Inverter - 3kW AIMS  pure sine
Solar - considering addding 220W with MPPT Make Sky Blue 30A
Set up for mobile gastronomy 2kW cooling compressor + 500W appliancies
Spot Welder - Mactronic V3.
Reply
#16
I took the home brew MOT spot welder route.

Works very well, over 5000 welds in so far and still going strong.


UK Southwest.

7 kWp Solar Panels (28 x 250Wp Shinetime Mono).
14 X APS YC500i Micro Inverters.
28 X 40P 18650 cell packs/modules configured as 14S 80P.
Sofar Mass Energy ME3000SP AC coupled charger/inverter.
Still sourcing and processing cells for powerwall.
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#17
(07-25-2019, 08:53 AM)chuckp Wrote: I took the home brew MOT spot welder route.

Works very well, over 5000 welds in so far and still going strong.



That looks really good.
Can you tell us more about the spot welder you made?
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#18
(07-25-2019, 10:48 AM)Oz18650 Wrote:
(07-25-2019, 08:53 AM)chuckp Wrote: I took the home brew MOT spot welder route.

Works very well, over 5000 welds in so far and still going strong.



That looks really good.
Can you tell us more about the spot welder you made?

Sorry I didn't take any photos at the time, but here goes.

I had an old UPS for a PC that was no longer useful. I stripped it out just for the case as I thought it would make a good housing for the electronics.

I used a JST41-1200 Battery spot welding control board, 16 single chip microcomputer control, 1602 MCU LCD, encoder double pulse pcb to control the pulse duration. https://www.aliexpress.com/item/32810563725.html

Striped out an old 230V 850W microwave oven i had kicking around to salvage the transformer, cut out the secondary windings and removed the magnetic shims i replaced the windings with two turns of 16mm2 flexible battery cable with approx 1M of spare cable to exit through the case for each of the spark electrodes.

I mounted the MOT in the case along with the pcb and used a small 230V to 12V transformer for the pcb power supply. Cut the end of the case out and fitted an old PC fan on the end to keep everything cool, not that anything gets hot, I probably didn't need the fan. Pushed the battery cable out through a couple of holes drilled into the front of the case and cut holes for the display board and adjustment knob.

I soldered a couple of soldering iron tips into the ends of the battery cable for the electrodes and covered the ends with a few layers of heat shrink.

Used an old sewing machine peddle switch to operate the welder.

It works very well for welding fuses to cells with pulse power set to about 80% but I do need to have the pulse power set to 100% if I'm welding nickel strip otherwise the weld isn't strong enough.

I have now obtained a 1000W MOT that I'm going to fit in at some stage. I will take a few build photos when I get around to doing it.

I haven't measured the output amperage but I would imagine it's around the 450A mark, the voltage at the electrodes around 1.8V

I found that a two pulse weld works well on the fuses, P1 set to 65% for 70ms (to pre-warm the metal) a 25ms delay and P2 set to 80% for 90ms (for the weld).

The only purchases i made was for the JST41-1200, 230V-12V transformer and 2.5m of 16mm2 battery cable, the build cost was around £35 and a few hours of my time.
Ibiza and Oz18650 like this post
UK Southwest.

7 kWp Solar Panels (28 x 250Wp Shinetime Mono).
14 X APS YC500i Micro Inverters.
28 X 40P 18650 cell packs/modules configured as 14S 80P.
Sofar Mass Energy ME3000SP AC coupled charger/inverter.
Still sourcing and processing cells for powerwall.
Reply
#19
(07-25-2019, 01:23 PM)chuckp Wrote: The only purchases i made was for the JST41-1200, 230V-12V transformer and 2.5m of 16mm2 battery cable, the build cost was around £35 and a few hours of my time.

Thanks for elaborating on your build.

That is another option which I did not know before.
chuckp likes this post
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#20
(07-25-2019, 08:20 AM)Issac Wrote: @duwdu

Working very well, but I do not have comparision to k-weld.
As I remember I choose malectrics because they have confirmed working history with supercaps.

But I switched to lead-acid car battery, because caps didnt work. 
I think because they were old (2007 manufakture date ~10 years lifespan), even when charged to max they cannot give proper current, and welds were very weak. (with 6S2P configuration of 350F 2.5V charged to 13.5V it sucs..)

BMS board i bought on ebay, from seller that no longer exists. I did connect it later with extra copper wires blobed with solder, no change. 

I found on ali the same one:
https://pl.aliexpress.com/item/32813057355.html

Thanks for the insight on your user experience, Isaac, particularly the caps. Enjoy.

........
P34c3
.....
...
Reply


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