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'[EE]: Homebrew resistance welder'
2005\08\12@091822 by Philip Pemberton

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Hi folks,
 A while ago I mentioned that I was working on a homebrew resistance
welder... I've built a quick-hack version up today, sans controller board
(still can't get the damn thing working) to weld some nickel tabs onto
lithium coin cells.
 Photos online at <http://www.philpem.castlecore.com/welder/> if anyone's
interested. All it consists of is a bunch of Cornell-Dubilier computer-grade
electrolytics, and an International Rectifier SCR (which now has a chunk of
metal blasted out of the can after a minor incident involving slipping with
the -ve electrode). One channel of the PSU is used to charge the caps, the
other is used to fire the SCR.

 Comments welcome, both good and bad. :)

Later.
--
Phil.                              | Acorn RiscPC600 SA220 64MB+6GB 100baseT
spam_OUTphilpemTakeThisOuTspamphilpem.me.uk              | Athlon64 3200+ A8VDeluxe R2 512MB+100GB
http://www.philpem.me.uk/          | Sony MZ-N710 NetMD Minidisc
... See that potti, That's your tower system that is.

2005\08\12@100705 by shb7

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face
It looks like it does a great job on those coin cells. What are you using the gameboy cartrige for?



2005\08\12@103424 by Philip Pemberton

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In message <.....20050812.070610.23005.369043KILLspamspam@spam@webmail29.nyc.untd.com>>          "shb7spamKILLspamnetzero.net" <.....shb7KILLspamspam.....netzero.net> wrote:

> It looks like it does a great job on those coin cells. What are you using the gameboy cartrige for?

The FLASH cartridge? I'm using it to test some hardware that interfaces
through the link port. I've been using my EPROM emulator for most of the dev
work I've been doing, but for some things you just can't beat a FLASH cart
with a "real" Nintendo MBC.

Later.
--
Phil.                              | Acorn RiscPC600 SA220 64MB+6GB 100baseT
EraseMEphilpemspam_OUTspamTakeThisOuTphilpem.me.uk              | Athlon64 3200+ A8VDeluxe R2 512MB+100GB
http://www.philpem.me.uk/          | Sony MZ-N710 NetMD Minidisc
... Reactance: your imaginary friend.

2005\08\13@131045 by Gus Salavatore Calabrese

face picon face
> Hi folks,
>  A while ago I mentioned that I was working on a homebrew resistance
> welder... I've built a quick-hack version up today, sans controller  
> board
> (still can't get the damn thing working) to weld some nickel tabs onto
> lithium coin cells.



Hello Phil

did you mention what voltage you were using
and what the total capacitance was ?

It is not clear to me how you are triggering the
SCR.

How hard do you press the copper electrodes
to the material ?

In all the photos I looked at , it appears you are using the
wrong color wire.  How did you get that color to work ?


Cheers

Gus



Augustus Gustavius Salvatore Calabrese 720.222.1309    AGSC
http://www.omegadogs.com   Denver, CO

Disclaimer: The above statements are not intended as an endorsement of
any kind and any inference of having any verifiable knowledge about
anything referenced above is purely coincidental. ( we hope )

If you are not part of the solution, you are precipitate.





2005\08\15@045045 by Michael Rigby-Jones

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{Quote hidden}

I'm very interested in this Phil, could you give a few more details such as total capacitance and the voltage the caps are charged to?  How strong/repeatable are the welded tabs?

Regards

Mike

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2005\08\20@095402 by Philip Pemberton

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In message <RemoveME52E57A2F-1640-4682-B7BE-BCAF9A6F9367TakeThisOuTspamomegadogs.com>>          Gus Salavatore Calabrese <spamBeGonegscspamBeGonespamomegadogs.com> wrote:

> did you mention what voltage you were using

The PSU is a Farnell L30/BT -- 0-30V at 1A.
The cap bank consists of five Cornell-Dubilier 12000uF computer-grade caps,
good to 25V for a total of 600000uF or 0.6F.

> It is not clear to me how you are triggering the
> SCR.

The "Ch1 O/P Enable" switch on the PSU. One of these days I'll wire up a foot
switch...

> How hard do you press the copper electrodes
> to the material ?

As hard as possible.

> In all the photos I looked at , it appears you are using the
> wrong color wire.  How did you get that color to work ?

Wrong colour?! Colour doesn't matter. It's standard copper wire with PVC
insulation, good to 2A constant, unknown surge handling capability.
The relatively high resistance is pretty nasty for welding though - I need to
get some thicker wire for the electrodes and SCR.

I also managed to blow a chunk out of the £12 SCR's casing by shorting the
-ve electrode to the SCR's casing. Oops.

Later.
-- Phil.                              | Acorn RiscPC600 SA220 64MB+6GB 100baseT
TakeThisOuTphilpemEraseMEspamspam_OUTphilpem.me.uk              | Athlon64 3200+ A8VDeluxe R2 512MB+100GB
http://www.philpem.me.uk/          | Sony MZ-N710 NetMD Minidisc
... How's this for diplomacy?  Shoot them all!  --Kir

2005\08\20@095911 by Philip Pemberton

face picon face
In message <RemoveME23075D38FE1C8144847DFAECA3565F2704E54F70spamTakeThisOuTpai-smx-01.europe.bkhm.net>>          "Michael Rigby-Jones" <Michael.Rigby-JonesEraseMEspam.....bookham.com> wrote:

> I'm very interested in this Phil, could you give a few more details such as
> total capacitance

600,000 microfarads (five 120,000 microfarad caps)

>and the voltage the caps are charged to?

"Suck it and see". I usually charge to 12V and if that doesn't work I start
increasing the voltage in 1V increments until it produces decent welds.

> How strong/repeatable are the welded tabs?

Once the voltage and pressure for a particular battery is determined, they're
quite repeatable. And you can solder to the nickel, but tin the bit that will
be soldered before welding it to the battery. 600-grit silicon carbide
(wet/dry) paper is useful for getting rid of oxidation - a quick rub with the
WD paper, followed by a wipe with a paper towel and >90% isopropyl.

Later.
--
Phil.                              | Acorn RiscPC600 SA220 64MB+6GB 100baseT
EraseMEphilpemspamphilpem.me.uk              | Athlon64 3200+ A8VDeluxe R2 512MB+100GB
http://www.philpem.me.uk/          | Sony MZ-N710 NetMD Minidisc
Ever noticed how DOS never says "GOOD command or filename"?

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