The welding oscillator is primarily needed for welding in various fields of production. The oscillator is useful in that it can be used both in industrial production and in everyday life. The oscillator mechanism of action is the ignition of the welding arc. Meanwhile, a stable flame supply is maintained during operation. The most commonly used oscillator is the device brand OP-240.
Since welding is indispensable in many areas of production and domestic work, the demand for oscillators is always great. But it is not necessary to buy it at all. Do-it-yourself oscillator is not so difficult to make. This will only require the necessary materials and compliance with the recommendations below.
Principle of operation
A self-made oscillator for the inverter or a purchased device is used for the stable operation of the welding arc. The frequency is 50 Hz with a rated operating voltage of 220 V. At the output, these parameters can increase to 150,000-300,000 Hz and 2500-3000 V, respectively. With this operation, the oscillator creates pulses up to several tens of microseconds long. Similar parameters of work, when a high-frequency current passes into the welding circuit, are due to the corresponding power - 250-350 watts.
Composition
With these characteristics, the made aluminum oscillator with its own hands has the capabilities that correspond to the conduct of welding production or repair work in everyday life. It can be used 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 a capacitor for?
The capacitor in this circuit has an important function in protecting the device itself and the welding worker from various injuries caused by 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. Thus, it charges it. When fully charged, the capacitor transfers a current discharge to the spark gap, from which a breakdown is formed. Meanwhile, the oscillating circuit is shorting. This whole process causes oscillations according to the resonance principle. But they die out right away. High-frequency current for resonant vibrations enters the welding arc, bypassing the capacitor and coil.
Do not forget that the device of the blocking capacitor causes the passage of a high-frequency current through it, as a result of which there are high voltage values. Due to the resistance, together with the current blocking by the capacitor, the oscillator is protected against short circuits.
How is the process going?
To make the oscillator with your own hands, a high voltage transformer will be needed. It is required to increase voltage. Also, you can not do without a button on the heating pad. It serves both for supplying gas to the nozzle of the plasma-forming arc, and for controlling annealing. All this protects the metal from the effects of oxygen and makes it possible to form an argon atmosphere, in which the process of metal welding directly takes place.
The work process is as follows. After pressing the control button, the spark gap lights up, creating a pulse frequency. For this, the existing high-voltage transformer is fully responsible. A high magnetic field is created through an arc, after which it is converted by a coil. The latter is made 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 goes to the part. After pressing the control button, the gas enters the burner through the valve. This is the start of the welding process. Also, any oscillator, whether it is factory or home-made, must have a capacitor.
Before you start designing an oscillator for welding yourself , you should familiarize yourself with the drawings of its design in advance. If you even have basic knowledge in the field of electrical engineering, this will not be a particular problem. In addition, design experience is desirable. When making the oscillator yourself, you should remember that you must follow safety precautions. Since 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. For installation, one of the most commonly used schemes is used:
- The first step is to choose a reliable transformer so that it can provide an increased voltage supply from nominal 220 to 3000 V.
- After that, we install the spark gap passing spark gap.
- Next, we connect another important element - an oscillatory circuit with a blocking capacitor that generates high-frequency pulses.
That's all, the oscillator is ready. The main part of the circuit of this device is the oscillatory circuit. It must contain a blocking capacitor. An oscillating circuit, which also includes an inductor and a spark gap, is necessary to generate pulses. With their help, the welding arc ignites much easier.
Do-it-yourself bought or manufactured oscillator can be pulsed and continuous. But the latter option is less effective. In addition, an additional device will be required to protect against high voltage.
Manufacturing rules
Thus, if the device is planned to be used exclusively in everyday life, then it is best to make an oscillator for welding with your own hands, since it will be very expensive to purchase it from the manufacturer and dealer. To top it off, you must have the skills to assemble such devices and knowledge of electrical engineering.
If you intend to make an oscillator with your own hands, 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 if safety precautions are not followed, there is a high risk of personal injury. 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 an oscillator yourself will not be too difficult. You just need all the necessary tools and materials.