How to make an oscillator with your own hands for welding?

The welding oscillator is primarily necessary for welding operations in various fields of production. Oscillator is useful in that it can be used both in industrial production and in everyday life. The mechanism of the oscillator is the ignition of the welding arc. Meanwhile, a stable flame feed is maintained during operation. The most commonly used oscillator is the device of the brand OP-240.

Since welding is indispensable in many spheres of production and household work, the demand for oscillators is always great. It is not necessary to buy it at all. Oscillator with their own hands is not so difficult to make. This will only require the necessary materials and the observance of the recommendations below.

Principle of operation

A built-in oscillator for the inverter with your own hands or the purchased unit is used for the purpose of stable operation of the welding arc. The frequency is 50 Hz at a nominal operating voltage of 220 V. At the output, these parameters can be increased up to 150000-300000 Hz and 2500-3000 V, respectively. With this operation, the oscillator generates pulses of up to several tens of microseconds. Similar parameters of operation, when high-frequency current passes into the welding circuit, are due to the corresponding power - 250-350 W.

Composition

With such characteristics, the made aluminum oscillator with its own hands has those capabilities that correspond to the carrying out of welding production or repair work in everyday life. With its help, it is possible to weld aluminum and other metals.

Consider the electrical components of the oscillator:

• Arrester;
• Two coils of chokes;
• Transformers: simple and high-frequency;
• Oscillatory circuit.

A circuit consisting of a capacitor and a high-frequency transformer generates damped sparks.

What is the use of a capacitor?

The capacitor in this circuit performs an important function of protecting the device itself and welding the worker from various injuries caused by the impact of electricity. In the event of a breakdown, the electrical circuit is opened due to a special fuse. It serves as a protective element.

The joint operation of the apparatus and the oscillator occurs according to the following algorithm. Voltage is supplied through the transformer to the capacitor. So it charges it. When fully charged, the capacitor transfers a discharge of current to the spark gap, from which a breakdown is formed. Meanwhile, the oscillatory circuit is short-circuited. The whole process causes fluctuations in accordance with the resonance principle. But they immediately fade. The high-frequency current for resonant oscillations arrives at the welding arc, bypassing the capacitor and the coil.

We do not forget that the blocking capacitor device causes the passage of a high-frequency current through it, as a result of which there are high values of the voltages. Due to the resistance, together with the current blocking of the capacitor, the oscillator is protected from short circuits.

How does the process occur?

To make the oscillator with one's own hand, a high-voltage transformer will be needed. It is required to increase the voltage. Also you can not do without the button on the hot water bottle. It serves both for feeding gas to the nozzle of the plasma-forming arc, and for controlling the annealing. All this protects the metal from the effects of oxygen and makes it possible to form an argon medium, in which the process of metal welding itself takes place.

The work process is as follows. After pressing the control button, the arrester generating the pulse frequency lights up. The existing high-voltage transformer is fully responsible for this. A high-magnetic field is created through an arc, after which it is transformed by a coil. The latter is manufactured by winding with a conventional welding cable.

This design has two outputs - plus and minus. Both of them pass through a transformer. However, the first goes to the burner, but the second - to the detail. After pressing the control button, the gas flows through the valve into the burner. This is the start of the welding process. Also any oscillator, whether it is factory or homemade, should have a capacitor.

Before you start designing an oscillator for welding work yourself , you should familiarize yourself with the drawings of its design in advance. If there is even an initial knowledge in the field of electrical engineering, this will not be a problem. In addition, the experience of design is desirable. While doing the oscillator yourself, you should remember that you need to observe safety precautions. As there is a risk of electric shock.

Manufacturing procedure

In order to weld mainly aluminum parts, you can make a welding oscillator with your own hands. One of the most commonly used schemes is used for installation:

1. The first thing to do is to select a reliable transformer so that it can provide an increased supply voltage from the rated 220 to 3000 V.
2. After that, we install a spark gap.
3. Next, connect another important element - an oscillating circuit with a blocking capacitor, generating high-frequency pulses.

That's all, the oscillator is ready. The main part of the circuit of this device is the oscillatory circuit. In its composition there must be a lock capacitor. The oscillatory circuit, which also includes an inductor and an arrester, is necessary for generating pulses. With their help, the welding arc ignites much easier.

The bought or manufactured oscillator with its own hands can be pulsed and continuous. But the latter option is less effective. In addition, an additional device is required to protect against high voltage.

Production rules

Thus, if the device is intended to be used exclusively in everyday life, it is best to produce an oscillator for welding by one's own hands, since its purchase from the manufacturer and the dealer will be very expensive. To top it all off, you need to have the skills to assemble such devices and the knowledge of electrical engineering.

If you intend to manufacture the oscillator yourself, you need to pay attention to only the correct assembly, but also the competent operation of this device. After all, the device is powered by electricity. And with non-observance of safety precautions, the risk of injury is high. You should carefully approach the assembly of electrical circuits and apply only those parts that are fully suitable for their characteristics. If you follow all the recommendations, making the oscillator with your own hands will not be too difficult. You just need all the necessary tools and materials.