How to make a welding machine for wires with your own hands?

Before you make a welding machine for wires at home, it is worthwhile to understand the main components and principles of work. Particular importance is given to the power of the voltage, which depends on the type of work ahead. To connect metal thin products requires low current, while welding of massive reinforcement is not possible at this intensity.

Transformer

The device provides an arc from the mains voltage. This element consists of two main parts:

• Magnetic core;
• winding.

The creation of a transformer is not particularly difficult. The primary winding of the device is connected to the mains in 220 W, while the secondary is required for the welding work itself. Magnetic wire can be assembled not only from plates of special transformer metal, but also from other materials. As a supplement to improve the characteristics of the arc, special devices are used that provide a smooth voltage adjustment. Such additions are most often found in professional devices.

Depending on the strength of the current, the power of the transformer is selected. It should be noted that the voltage at the output terminals determines the progress of the welding process, which can be hard or more soft. This must also be considered before making a welding machine for welding wires.

When selecting a voltage source, it is necessary to repel the desired current characteristics. The best option will be sources with steeply falling and gently falling properties. They simplify the welding process and provide minimum arc fluctuations.

Required items

Independently, you can make a welding machine for wires of any type, whether it is automatic, inverter, operating on a constant or alternating current. In the absence of experience in carrying out such work, it is worthwhile to dwell on a simple transformer apparatus. Such a device operates on alternating current and allows achieving a quality welded seam. It is optimally suited for welding wires at home. Before you start making, you need to prepare the following:

• Material for the core of a transformer with a high level of magnetic permeability;
• Enough copper wire.

The core must have a U-shaped standard configuration and a rod structure. In some cases it is necessary to use cores of another shape (for example, round ones), this does not change the characteristics of the device, but complicates the winding of the wiring. For a household appliance, the cross-sectional area of the core should be within 50 cm². The use of a large cross-section is impractical, since it does not provide additional characteristics and increases the total weight of the device.

Winding

For the primary winding, copper wiring is used, characterized by a high level of resistance to thermal effects. It should be supplemented with glass-fiber or cotton insulation. It is possible to use cables with an insulating sheath of rubber and other materials, except for PVC.

If necessary, the insulation can be made by hand with the help of small pieces of suitable material. They are wound on a copper wire and covered with a layer of electrical varnish.

The frame of the coils is manufactured in accordance with the geometric characteristics of the magnetic circuit. They must have suitable dimensions so as not to interfere with the free placement of the magnetic circuit on the core. For the manufacture of the latter, as a rule, ordinary cardboard or textolite is used.

What you need to know

When winding the coils, it is necessary to take into account some features. In particular, the primary winding is made only half, on top of it is superimposed a part of the secondary. The other side of the coil is wrapped in the same way. With the help of thick paper, fiberglass and cardboard, it is possible to increase the insulation properties, for this it is necessary to lay the pieces of the selected material between the layers of the winding.

The welding machine for copper wires also requires adjustment, which consists in connecting the device to the network and measuring the voltage data on the secondary winding. Indicators should be within 60 V. If necessary, you can add part of the winding or remove excess. Measurements and changes in the winding are carried out until the required data are obtained.

The welding machine for wires is connected to the network by means of a two-wire cable or an internal gasket that connects to the primary winding. The last step is the connection of the PGG wires to the terminals of the secondary winding. It is worth noting that these wires fix the base of the welding rods and connect with the processed elements.

Working with copper wires

In electrical work copper wires are indispensable. There are three main connection methods: welding, clamping and crimping. The optimal combination of speed and quality of work is the first option.

Care should be taken when working with copper and take into account the characteristics of this material. It is susceptible to breakage even with a slight heating, despite the fact that its melting point exceeds 1000 degrees. Welding works can be performed by direct and alternating current. If necessary, an arc welding method and additional apparatuses such as a transformer, a beam device and an inverter can be used.

Stages of work

The welding machine for welding wires can be of different design and manufactured according to a certain technology, despite this, the welding process consists of identical steps. To begin with, the sheath is removed from the cables using scissors or a conventional clerical knife. It is necessary to retreat from the edge for 2-3 cm, prune the upper shell and gently pull it off. The twisting of the cables should have a length of about 3 cm and be supplemented with several cores of standard size. The clamp is fixed only on the finished connection. Next, you need to connect a welding machine for welding copper wires with installed power and amperage.

What you need to pay attention to

The welding process itself takes several seconds and provides a small copper ball. It should be noted that the welding time is of particular importance, since if the machine is removed too soon, the quality of the connection will be low because of the porous structure. In this case, if you overstay for a few seconds, you have to start all over again, since the ends of the cables completely melt. After connecting and cooling of the elements, it is necessary to make insulation and connect the voltage.

Choice of cables

Taking into account the fact that the welding machine is connected to the network by copper wires, their choice is no less important. They should provide work under different voltage levels and in different conditions. No less important are the following characteristics:

• Resistance to bending and other mechanical influences;
• Preservation of characteristics when exposed to ultraviolet radiation;
• The possibility of using in a wide temperature range;
• Resistance to mold and corrosion.

Device from microwave parts

A simple welding machine for copper wires with their own hands can be made from a transformer from a microwave oven that has high power and compact dimensions. A similar device is placed in the housing from the PC power supply and is ideally suited for welding copper cables.

To create the device, a transformer from any microwave oven is suitable. It must be previously disassembled, this can be done by cutting the sides using a Bulgarian. It is worth noting that the connection of the transformer to the network is possible only after removing the secondary winding.

It is necessary to wind the secondary winding instead of the old and seal the core with an epoxy compound. Then it remains to install the transformer in the housing from the power supply unit together with two automata.

The obtained welding machine for wires provides fast ignition of the arc and qualitative processing of cables. The transformer does not heat up during operation, but when using a larger device it is recommended to use a 10 mm² conductor for the winding. Despite the fact that the transformer is quite noticeable weight, the device itself has small dimensions.

Simplify the use and improve the quality of the connection by using a switch located on the handle of the graphite terminal. This way it will be possible to turn on the machine after the twisting is set to the desired position.

Welding machine for wires by own hands: features

Softer welding is obtained by using a throttle. It should be noted that when working with copper twists, there is a sharp smell of fumes and smoke, so it is recommended to open the window first. Cases of ignition of a graphite electrode are also not rare.

Wires must be of the same length. It will also be useful to cover the brown twist before welding and observe the minimum heating time.

A good terminal can be obtained from improvised items or parts purchased for a symbolic value. For this role, a brush from a trolleybus or a powerful motor is perfect. In the graphite, several holes of suitable size are drilled. They are necessary for laying twists and getting an even alloy.

The arc during operation must be continuous and have sufficient heating to ensure a good connection. As noted earlier, heating to a temperature below the required level leads to the formation of a porous core within the frozen droplet.