Electricity is provided for residential buildings and production areas with electricity. Experienced workers use factory welding machines for twisting coils in their work. And they are confident in the quality of the installation. But homemade devices are not inferior in the quality of their work.
Types of welding machines
Today, there are many devices that can ensure the smooth operation of electricians. Some of them are quite expensive, others are free of charge engineering.
The following types of welding machines for welding copper twists are used:
- Professional tooling designed and manufactured by the industry. Import and Russian production. For example, an industrial machine for welding strands TC-700.
- Inverters Rectifiers capable of welding ferrous and non-ferrous metals.
- Self-taught welders.
Homemade twist welding machine
When a person thinks about buying such equipment, he begins to reflect on whether it can be done independently. Indeed, many electricians with extensive experience in handling electrical equipment have realized the idea of making a machine for welding twists with their own hands.
Basic concepts:
- Current indicated in amperes.
- Voltage measured in volts supplied to the welding machine.
- Type of current. There is direct and alternating current required by welding units.
Rich work experience prompted them to use a transformer from a broken microwave. Such a unit is capable of producing 4 kW.
The main stages of work:
- Carefully disassemble the microwave.
- Transformer free from all unnecessary.
- Upgrade the transformer for the required purpose.
Disassembling a transformer requires special attention. It is better to choose it with power from 700V to 1000V. The welding seam can be sawed by a grinder with a thin circle. From the extracted microwave material, a magnetic circuit is useful, the transformer itself, having a thicker section of the primary winding wire and a small number of turns.
Modernization
The primary winding will suit us perfectly. The next thing to do is throw out the secondary. An ordinary chisel and a bench tool will help us remove it. Carefully removing and stripping the secondary winding, you need to look at the magnetic circuit, if there are shunts, they will have to be dismantled. The secondary winding of the new apparatus for welding copper strands must be made with a cross section of 15-20 m² . About 12-13 turns.
If it is not possible to find the necessary copper core, you can use a twist, that is, several stacked parallel wires. The main condition from such a twist is the final result - a tire of 15-20 m² should be obtained.
For insulation, fabric insulation is suitable. Having made and insulated the copper bus, we will carefully manufacture the secondary winding of the transformer. The measured voltage should be from 9 to 36 volts.
Having thus modernized the transformer of the twisting machine, we proceed to the manufacture of the remaining elements of the welding machine. To do this, make sure that some important conditions are met. The wires from the upgraded transformer to the device for welding the twisted wires should be a cross section not less than the secondary winding, that is 15-20 mm². It must be noted that during the welding process the wires become very hot. The heating of copper is fleeting.
Holder and weight
In the process of working at height, the convenience of the holders for welding wires is of great importance.
The best solution is to use carbon electrodes. Some use battery-powered rods of carbon electrodes in home-made welding machines for twisting.
Many use simple brass crocodiles to hold the graphite electrodes out of the battery. But as mentioned above, the heating of wire elements and various devices in the welding process is large. "Crocodiles", heating up and charring, lose their intended purpose. The material becomes soft and cannot hold the electrode.
Carbon Electrode Application Techniques
Consider one of the most rational ways to use a carbon electrode. A carbon brush was taken, in which several recesses were previously drilled for welding copper twists of various sections. The brush must be taken from a high power electric motor.
On the graphite brushes there are conclusions to which you can successfully solder the wires from the twist welder.
To make such a brush comfortable to hold at a height, a holder is needed. Will have to make a homemade clamp holding it. Attach a pen to it. You can take a handle from a chisel or file. Modern chisels use a material that does not transmit current, which is very good for work. A holder made in this form is very convenient. The twist inserted into the drilled recess perfectly welds and has a neat appearance.
Making a second holder for welding
The second wire from a home-made machine for welding twists is very well connected with pliers. The connection must be fixed on the handle with pliers using soldering. Various soldering methods for steel and copper are available. It is easier to use a copper tube, at the end of which the second wire of our homemade product is inserted and sealed. The pipe is also soldered to the pliers. This design is very convenient and reliable. To work efficiently, it is good to drill a pair of holes for twisting wires of various cross-sections in the jaws of pliers. The maximum length of the wires is not more than 3 meters. Otherwise, resistance increases.
How to make a welding machine switch?
One of the conditions of convenience in work is direct contact of the twisted wires with the mass from the welding equipment and holder.
Working with constantly turned on equipment requires a lot of experience. When the mass and the holder come in contact, lightning contact occurs, which is not very good when working with a stepladder or ladder.
People who were able to make a welding machine for welding twists with their own hands, solved this problem simply. The switch connected to the primary winding, they installed on the handle of the holder.
When the power is off, the twist of the wire is quietly installed in the recess on the brush. After the twist is installed, voltage is applied and welding mode occurs. Brewing the twist, the power is turned off and time is given for cooling the twist. The work is safe and convenient.
Pliers, in addition to the function of the holder, play the role of heat sink. The temperature that occurs during the welding process heats the pliers, thereby the wire going to the transformer does not overheat. Work with such equipment is no worse than with a vehicle for welding twisting. It is advisable not to forget to put in the home-made two single-pole machines that protect the windings from overload.
Device body
The casing for your home-made welding machine for welding strands of wires can be made from various failed devices and equipment located in the housing. At home or in the garage there is sure to be an old household appliance that can be used for a really worthwhile business.
To do this, the housing of the oscilloscope, computer and other suitable equipment in size should be suitable, preferably with slots in the cases for ventilation.
The basis for a home-made welding machine is best made from textolite or getinaksa. Having thus removed our home-made welding unit in the body, we will produce a device for the belt, which is necessary for work at the construction site. Having hung your welding device on your shoulder, it is convenient to work with it on a stepladder.
What you need to know about preparing wires for twisting?
The wires must be stripped from insulation by about seven centimeters. This is done so that it does not melt during the twist welding process. Also, do not forget to leave wires of sufficient length during electrical installation in junction boxes. After twisting the wires, remove their excess length using side cutters. Having bitten off the excess, you can get a neat twist, convenient for welding, and after welding the twists, have a high-quality and reliable connection.
At this stage, we can assume that the homemade device for welding twisting is ready. It remains only to test it in action.
Conclusion
The use of a strand welding machine TC-700 2, of course, is convenient. The light weight of 4.5 kilograms in a reliable case on the belt ensures its mobility.
A reliable electrode withstanding up to 1 thousand welded pulses makes it a welcome tool.
But the average cost of 10 thousand rubles is not for every electrician in the teeth. So why not do a do-it-yourself welding machine and pack it in a protective casing and equip it with a belt? It will become as easy to use as branded welding equipment.
Anyone who is a little versed in the field of electrical engineering can make a home-made apparatus for welding copper coils by applying these recommendations. The cost of homemade equipment is lower than factory analogues. However, the reliability and quality of the welding work will be at a height that has been recorded many times.