Title: Making a welding machine from a computer power supply Publisher: Praktik-Tsentr Year: 2009 Pages: 11 Language: Russian Format: pdf Quality: excellent Size: 4.98Mb

This small brochure provides an example of how, based on an AT computer power supply, you can make a small-sized and lightweight device for small welding jobs that do not require high current, which can be plugged into almost any outlet without fear for the safety of the wiring.

In the amateur radio environment, the diotactic forward quasi-bridge converter, or in common parlance an “oblique” bridge, has become the main type of converter for constructing welding current sources. However, many industrial welding inverters, up to a load current of 250A (for example, liSAB Caddy Professional 250), use this circuitry.

This work presents an attempt to make a small-sized and lightweight device for small welding jobs that do not require high current, which can be plugged into any outlet without fear for the safety of the wiring. The entire welding unit was placed in a case from an AT computer power supply; a radiator from PIV was used as a cooler, cut into 3 parts; IRG4PC50U transistors were installed on the two smaller parts, and KD2997A output diodes were installed on the larger part. Transistors and output diodes are installed on radiators without gaskets! Everything is blown through a fairly powerful Thermaltake A2016 fan, 80x80mm, 0.48a, 4800 rpm, the fan has a built-in speed control depending on the temperature, the sensor is a thermocouple installed on the heatsink of the output diodes. It was also necessary to drill additional holes in the case for better cooling, since the installation turned out to be quite tight and the existing holes on the front of the case were not enough. Overheating protection operates at approximately 70-72 degrees on the transistor radiators.

Despite the small size and weight of the PB, it seems to me that it turned out to be quite decent, about 100% at currents up to 80A, and at 100A it is already possible to cook tolerably with three...

delayuvsesam.ru

Most welding machines have inverter circuits, where field-effect transistors are used as power switches. This scheme allows you to reduce the weight and size of the installation. Today, taking advantage of a wide assortment, you can buy a welding machine in a store, but it will most likely have a principle of operation that is similar to that of the others.

In order to make a welding inverter yourself, as well as if it needs to be repaired, you should familiarize yourself with its structure.

Characteristics of the future welding inverter

The installation must contain some elements, including:

• power switch driver;
• power component;
• power unit.

The welding inverter, the independent production of which will be described below, will have the following characteristics:

• welding current can reach 250 A;
• standard network voltage is 220 V;
• the highest current consumption is 32 A.

Using such a setup, it will be possible to work using an electrode with a diameter of 5 mm, and the length of the arc can reach 1 cm. The performance of the device will not be inferior to what can be purchased in a store.

Welding inverter manufacturing technology

Figure 1. Inverter power supply diagram.

In Fig. 1 contains a diagram of the installation’s power supply, which should help craftsmen who intend to carry out the work themselves.

In order to achieve balancing of the voltage indicator, windings should be made to the width of the frame. In general, their number should be limited to four:

• primary - PEV 0.3 mm, 100 revolutions;
• secondary (2) - PEV 1 mm, 15 revolutions;
• secondary (3) - PEV 0.2 mm, 15 revolutions;
• secondary (4) - PEV 0.3 mm, 20 revolutions.

It is recommended to install the board on which the power supply will be mounted separately.

It is separated from the power component by a steel sheet, which is attached to the body.

Conductors that have a purpose expressed in controlling the gates should be soldered as close as possible to the transistors; they must be twisted together so that they form pairs. The cross section is not critical, but the length of the conductors should not be given more than 150 mm.

When making inverters with your own hands, you should use circuit diagrams. One of them, with a picture of the power section, is shown in Fig. 2. The block (Fig. 3) in such an installation is represented by a regular flyback. The primary of the transformer unit should be protected with a shielding winding made of the same wire.

Figure 2. Diagram of the inverter power section.

In this case, the laid turns must completely overlap the primary, and their direction must coincide. Insulation from masking tape should be placed in the space between them, the latter of which can be replaced with varnished cloth.

To equip the power supply, you should select a resistance so that the voltage supplied to the relay is equivalent to a value in the range from 20 to 25 V.

The diagram presented above displays all the characteristics of the power section. The highest priority for input rectifiers is to select high-quality radiator components. Those that were installed in old computers that operated on the basis of Pentium 4 or Alton 64 processors are perfect. You can purchase them on the secondary market for a symbolic price.

The control circuits of the described installations have a thermal sensor in a single copy. It should be located in the internal space of the radiator housing, the heating temperature of which is the highest.

In order to make a control unit, you should purchase a PWM controller. It operates only from one control channel, through which the current in the arc is adjusted. The welding inverter circuit allows you to determine the location of capacitor C1, which will determine the PWM voltage; the magnitude of the current during welding depends on the latter characteristic.

Tools and materials

Figure 3. Inverter power supply diagram.

To carry out the process of manufacturing welding inverters with your own hands, you will need to prepare:

• masking tape;
• PWM controller;
• system unit of an old PC.

Depending on the scheme that will be used in the work, other components can be used to carry out the work.

Alternative inverter manufacturing option

To make a welding inverter with your own hands, you need to use a 40 mm copper strip, the thickness of which is 0.3 mm, and use it to wind it. As a thermal layer, you need to use paper from a cash register. You can use another one that has similar characteristics; the only requirement for this component of the winding is the strength of the material. It is worth considering that as the machine operates, the paper will begin to darken, but this will not in any way affect its technical and strength characteristics.

Winding with thick wire cannot be done, despite the fact that some craftsmen do just that.

https://moyasvarka.ru/www.youtube.com/watch?v=LvIyLUOzS64

This requirement is due to the fact that this can cause overheating of the transformer. The secondary can be equipped with 3 strips of copper, which can be separated by a fluoroplastic layer. In this case, high-quality durable paper is also used.

Transformers of welding inverters are supplemented with fans, since the winding will heat up in any case. It is permissible to use a cooler from a 220 V system unit. It will be enough to equip the inverter with 6 fans, half of which should be directed directly to the motor winding. It is unacceptable to forget about air intakes; it is necessary to install them opposite the fans, this will eliminate the obstacle to the intake in the required quantity.

Welding transformer diagram.

Next, the inverter design must be equipped with a power oblique bridge on two radiators. In this case, the upper part should be located at one end, while the lower part can be strengthened by means of a mica spacer on the remaining bridge. The leads of the diodes must be positioned towards the transistors. The board must contain 14 capacitors of 0.15 microns and 630 V, their presence is necessary to reduce resonant emissions.

To ensure the lowest IGBT losses, snubbers should be installed in a chain, which will be supplied with capacitors. It is recommended to use only high-quality devices, even the simplest inverter. As an optimal option, you can use the SVV81 model. Although the IGBT opens in a shorter time, the reverse process requires a much longer period.

Even if during production you use welding inverter circuits and do the work correctly, this does not mean that you will be able to easily set up the machine at the last stage. Initially, you need to supply power to the PWM, the mark should correspond to 15 V, at the same time you need to apply a discharge to the cooler, this will allow you to start the cooling system, and you need to analyze the synchronism.

It is necessary to check whether the operation of the inverter resistor closure relay has started, which will happen after a maximum of 8 seconds of connecting the PWM board.

https://moyasvarka.ru/www.youtube.com/watch?v=Bf_4AbNBF7M

It is also necessary to check the board; rectangular pulses should be identified after the relay operates. Then power is supplied to the bridge, which will make sure that it is working properly, and it is worth setting the idle speed.

You can make a welding inverter with your own hands using different diagrams, instructions and drawings, but it is worth checking whether the transformer phases are installed correctly. This can be done using beam oscilloscopes. The first beam must be thrown onto the primary winding, the other - onto the secondary. In this case, the voltage should not jump more than 330 V at the lower emitter. In order to determine the operating frequency of the device, you should lower the PWM frequency until a bend appears on the lower IGBT. The resulting value must be noted, then the number must be divided by 2 and the oversaturation frequency added.

https://moyasvarka.ru/www.youtube.com/watch?v=dKRTeptgkYg

Test power supply to the bridge should be carried out using any household appliance; 2200 W is recommended. The most suitable device option is an electric kettle. It is important to remember that the driver bridges should be located under the heatsink above the IGBT, but they should not be installed closer than 3 cm to the resistors. It is not recommended to place the conductors connecting the optocouplers and PWM near the source of interference; they should be short.

moyasvarka.ru

Do-it-yourself welding inverter manufacturing technology

• 03-02-2015

• Creating a power supply for a welding inverter
• DIY inverter power part
• Operation of the welding inverter cooling system
• Inverter setup

You can find a welding inverter in any specialized store selling electrodes and welding equipment. You can purchase it at a fairly high price, but if you have basic knowledge of electronics and know how to use a soldering iron, you can assemble a welding inverter with your own hands, which will not be inferior to the factory analogue.

Diagram of a welding inverter.

Initially, you should familiarize yourself with all the main nuances and aspects of this matter: diagrams, drawings, instructions and the assembly process itself.

Homemade welding inverter

A homemade welding inverter is designed for long-term operation; it can work with electrodes whose diameter reaches 4 mm. Among its advantages is a large current reserve. The circuit of such a device is a single-cycle inverter that operates on processor control and uses digital induction. The characteristics of the inverter are presented below:

1. The maximum current value at which the welding inverter can operate reaches 220 A.
2. The no-load current is 30 A.
3. Induction support mode - three-digit indicator.
4. Its operation can be carried out using power from a household network of 220 V.

Among its functionality are the following:

Scheme of operation of a welding inverter.

1. You can adjust the current at which welding is performed; it varies from 30 to 220 A.
2. You can display current and temperature.
3. One of its important functions is the “anti-stick”, this function performs the action of turning off the device when the electrode begins to stick.
4. Homemade inverter circuits will allow you to add such features as hot start and idle.
5. You will be able to enable sleep mode on the inverter.
6. One of the features of such a device will be the ability to display events occurring in it using a three-digit indicator. This system is fully automated.

The circuit of this welding inverter consists of three main blocks:

1. The first block that is needed to create an inverter is a power supply.
2. The second component of the circuit is the rectifier block.
3. The final block is the inverter itself.

To create an inverter yourself and fully implement the circuit, you will need to purchase microcontrollers and other boards that will be required for its assembly.

The power section diagram is shown in Figure 1.

Home electric welding machines

Welding machine from a computer power supply

(Click on the pictures to enlarge them)

Components before assembly

Complete device

Test of strength

Weight about 2.5 kg

My device modifications

Super Doc | SDoka.ru - Website for craftsmen and handicraftsmen

In the amateur radio environment, a single-cycle forward quasi-bridge converter, or in common parlance an “oblique” bridge, has become the main type of converter for constructing welding current sources. However, many industrial welding inverters, up to a load current of 250A (for example, ESAB Caddy Professional 250), use this circuitry.

This work presents an attempt to make a small-sized and lightweight device for small welding jobs that do not require high current, which can be plugged into almost any outlet without fear for the safety of the wiring.

The entire welder fit into a case from an AT computer power supply, a radiator from PIV was used as a cooler, cut into 3 parts, IRG4PC50U transistors were installed on the two smaller parts, and KD2997A output diodes were installed on the larger part.

Transistors and output diodes are installed on radiators without gaskets! Everything is blown through a fairly powerful Thermaltake A2016 fan, 80x80mm, 0.48a, 4800 rpm, the fan has a built-in speed control depending on the temperature, the sensor is a thermocouple installed on the output diode radiator. It was also necessary to drill additional holes in the case for better cooling, since the installation was quite tight and the existing holes on the front of the case were not enough. Overheating protection operates at approximately 70-72 degrees on the transistor radiators.

Despite the small size and weight of the PV, it seems to me that it turned out to be quite decent, about 100% at currents up to 80A, and at 100A it is already possible to cook tolerably with a C grade.

Below are diagrams and drawings for making a welding machine from a computer power supply.

Electrical circuit diagram (click to enlarge):

PCB layout:

(click to enlarge):

Indicators on the oscilloscope (from left to right, top to bottom):

1) At the gate of the lower transistor: 160 A, 32 V.
2) At CT load: 160 A, 32 V.
3) On the reverse diode, xx.
4-5) Collector - emitter IRG4PC50U, almost xx.
6) Collector - emitter of the lower transistor: 160 A, 32 V.

Components before assembly:

Complete device:

Test results (click to enlarge):

Source - http://istochnik-m.ucoz.ru

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How to assemble a good homemade welding machine?

A homemade welding machine, when assembled correctly, will do its job no worse than a factory-made unit.

A welding machine is a technical device designed to connect various types of parts by heating them.

Existing schemes make it possible to assemble devices even from old computer units and televisions. But it is recommended to start such work if you have at least basic skills in working with electrical appliances.

Preparing to assemble the device from a computer power supply

A simple and very effective welding machine can be assembled using an old computer power supply. To assemble such a homemade device you will need the following:

During the assembly of the welding machine, a multimeter will be needed.

1. Soldering iron.
2. Electrical insulating tape.
3. Multimeter.
4. Tester.
5. Pliers.
6. Several screwdrivers (flathead, Phillips).
7. Solder.
8. A screwdriver or a drill with a screwdriver function.
9. Screws.
10. Alligator clips.
11. Wires of suitable cross-section.

Such a homemade device will be assembled using a case and some spare parts from a computer power supply. Cooling is very important. Test the fan in several modes. It must be of sufficiently high power. A thermocouple must be installed.

The most convenient handle for the operator is attached to the upper end of the power supply. For fastening, use screws of sufficient length. It is important that they do not reach the internal circuit.

Drill several additional holes in the case for more efficient cooling of the device. The quality of ventilation directly affects how long the future welding machine can operate.

Figure 1. Transformer diagram.

The scheme involves the use of three transformers. The transformer diagram can be found in Figure 1. Transformers of the ETD 59, E20 and Kx20x10x5 series are suitable. You can wind them yourself. Additionally, you will need a current transformer. Usually the product of the K17x6x5 series is used.

To make your own transformer, use a new enamel wire f1.5 or f2. Winding is carried out on getinax coils, crimping with wooden blocks, and impregnation with epoxy resin.

A transformer from a microwave oven is also suitable, but you need to reduce the number of turns of the secondary winding. This requires additional calculations to be performed in advance. This is a more economical option, but it requires significantly more effort and time. In practice, it is much easier to buy a ready-made transformer.

Step-by-step instructions for assembling the welding unit

The circuit based on a computer power supply has been tested by more than a dozen welders. Such homemade welding machines require replacing 15tb60 diodes with 25tb60 diodes. In practice, it has been found that this improves the performance of the unit. Diodes 150ebu02 need to be installed in groups of 2.

For additional savings, you can cut the PIV into 3 parts and use this design instead of a radiator. The design necessarily includes a forward-flow single-ended quasi-bridge converter. It is also known as the “oblique bridge”. It is recommended not to skimp on this element. It is better to buy a new high quality part.

During the process, you will need a tester and a multimeter. They will allow you to assemble the circuit as accurately as possible and in the shortest possible time. A homemade device can be connected to the network only after preliminary testing.

Output diodes and transistors are installed on radiators without the use of additional gaskets. Overheat protection should be set to 70 degrees. You can do this using a thermocouple.

After connecting all the parts into one structure, place them inside the housing and perform the correct wiring. The toggle switch for turning on the unit will serve as a switch for the future welding unit. The contact holders and current regulator should be placed on the front panel. The housing must be secured as firmly and carefully as possible.

The manufacture of such a welding machine does not require a lot of money, but it does require effort and time. If you wish and have the necessary skills, you can make individual changes to the circuit and get a welding machine with the characteristics you need.

Homemade resistance welding machine

Figure 2. Diagram of the electronic unit for resistance welding.

A welding machine of this type will help you connect a wide variety of metal products. Current passes through the junction, which leads to its deformation. There are spot, butt and seam methods of such welding.

Before starting to manufacture such a unit, choose the type that suits you best. The contact welding machine can be made stationary, suspended or mobile. Most often, such units are used for welding wires and various pipes. But you can adapt it to connect almost any product. The circuit diagram of the electronic unit of such a device is shown in Figure 2.

Take into account the fact that such a welding machine consumes a lot of electricity when operating. It can be used for welding parts with a thickness of 0.09-0.9 mm. It consists of 2 main elements: a power supply unit, which includes a transformer and a relay, and a gun.

An electrode is connected to the first winding via a cable. During welding, the second terminal must be connected to the product being welded. The welding gun consists of 2 elements of the same size and shape. You can use getinax, textolite and other insulators. To assemble such a welding machine, you will need:

1. Transformer.
2. Tester.
3. Several screwdrivers.
4. Power unit.
5. Adapter.
6. Lamp.
7. Cable.
8. Lock nut.

A small switch, lamp holder and adapter are attached to the front. You need to place a backlight switch at the back. The cover is connected with screws. The welding cable is connected to the adapter.

During the assembly process, you need to take into account the dimensions of the selected power supply and transformer. An important characteristic of a transformer is the cross-sectional area of ​​the magnetic core. It must exceed 60 cm².

The primary winding is made with 160-165 turns. It must be placed on one side of the magnetic circuit. Insulation is carried out using wooden wedges. It is necessary to create a bend on the secondary winding. This is done using loops. The bend will make it possible to fix the welding cable using special bolts.

The layers of the primary winding are insulated with fluoroplastic or electrical tape. Tape is used for fixation. The magnetic core must be tightened with corners and M8 bolts. To straighten the plate, a tie is performed. The frame is fixed using wooden wedges.

After this, you need to check the operation of the transformer. Connect it to a 220 V household power supply and at the same time measure the voltage on the second winding. It should be 41 V.

The auxiliary transformer will provide a voltage of 6-15 V on the second winding. For its manufacture, a magnetic circuit of 1 cm² is used. The windings between the magnetic core must be insulated with tape.

Do-it-yourself full-fledged inverter welding machine

Figure 3. Schematic diagram of a welding inverter.

The design features of the welding inverter make it possible to significantly reduce the dimensions and weight of this unit. There are many models available for sale with different characteristics that allow you to perform a wide range of tasks. But if you don’t want to spend money on buying a ready-made unit, you can assemble it yourself. You just need to understand the operating features and operating principles of the main internal circuits and elements. A schematic diagram of a standard inverter can be found in Figure 3.

The welding inverter is assembled from a number of elements, which include a power supply, power section and power switch drivers. This example describes step by step the manufacture of a homemade inverter with characteristics such as:

1. Maximum current consumption is 32 A.
2. Welding current – ​​no more than 250 A.
3. Mains voltage – 220 V.

When operating such a device, an arc up to 10 mm long will be created. The efficiency, provided that it is properly assembled, will not be inferior to that of factory-made inverters.

Diagram of a transformer with primary and secondary windings.

To equalize the voltage, you need to wind across the width of the frame. There will be 4 windings in total:

1. Primary of 100 turns, PEV 0.3 mm.
2. Secondary of 15 turns, PEV 1 mm.
3. Secondary of 15 turns, PEV 0.2 mm.
4. Secondary of 20 turns, PEV 0.3 mm.

The bracket with the power supply is fixed separately. It is separated from the power part using a metal sheet. The sheet itself is electrically connected to the weld body.

The conductors for controlling the gate are soldered at the minimum possible distance from the transistors. They twist together in pairs. The cross section does not have a special role, but it is important that the length of the conductors is no more than 15 cm.

The functions of the power supply are performed by an ordinary flyback. The shielding winding must cover the primary winding of the unit. The primary turns must be completely overlapped by the superimposed turns. They must also have the same direction. Between them is insulation made of varnished fabric or masking tape.

The final stage of inverter assembly

It is important to configure the power supply correctly. You must select a resistance such that the voltage supplying the relay would be 20-25 V. Make input rectifiers using high-quality, powerful radiator elements. For this task, you can use models from old computers from the Pentium 4 era. You can purchase the necessary parts on the radio market for a few dollars.

A thermal sensor must be installed in the interior of the case. This element will heat up the most. The control unit itself must be equipped with a TL494 PWM controller. It works with one control channel and is responsible for stabilizing the current in the arc. The PWM voltage is controlled by capacitor C1. Together, these elements influence the amount of welding current. This is just one of many options that exist. If necessary and if you have the appropriate knowledge, you can make your own adjustments.

Thus, there are no super-complicated steps in assembling a welding machine yourself. Even an old computer power supply or microwave oven can be used for this. You just need to do everything according to the instructions, strictly following each step of the manual. Good luck!

Welding machine from a computer power supply - a cheap solution for an electrician

• Selecting a transformer for a welding machine
• Recommendations for installing other parts of the circuit
• Installing a soldered chip into the case

Very often, welding work requires an inverter, thanks to which you can get high-quality seams and not take risks when working with gas welding. But purchasing such a device is associated with significant costs, so you can try making a welding machine from a computer power supply. For this you need not only spare parts, wires and a soldering iron. But also skills in electrical engineering, without which you can burn electrical wiring or get an electric shock.

The main components of the welding machine design.

Assembly, installation and subsequent testing can only be carried out if you have experience in rewinding transformers, assembling circuits and creating electrical devices with your own hands. If such knowledge is absent, then it is best to purchase a ready-made inverter and not expose yourself or others to danger.

Basic installation tools

Classification of welding transformers.

If you have experience and knowledge in the field of electrical engineering, then you can explore several options on how to make a welding machine from a computer unit. Basic tools that will be needed for all types of assembly:

• soldering iron or soldering station;
• tester;
• multimeter;
• electrical insulating tape;
• solder;
• screwdrivers with different tips;
• pliers;
• screws;
• screwdriver or drill;
• crocodiles;
• wires of the required cross-section.

To recreate the circuit of the welding machine, you will need all the spare parts indicated in the circuit, getinaks and solutions for transferring the printed circuit board to the workpiece.

To make your work easier, you can purchase an electrode holder and welding cables at the store. You can do it yourself by selecting wires of the appropriate cross-section and soldering crocodiles to them, remembering to observe the polarity.

Welding inverter circuit.

If you have a non-working computer system unit, then you need to remove the main battery from it and prepare it for dismantling. Sometimes, to create a powerful welding machine, they even use the system unit itself, installing wheels on it at the bottom and increasing the number of ventilation holes. The advantage of computer cases is that they are lightweight, easy to cool and already have ventilation.

The welding machine will require disassembling the power supply.

The main things that can be used from it are the fan, the housing itself and some spare parts. But it all depends on the modes in which the cooling operates. The fan must be checked for functionality and tested in several modes. It is advisable to install another one of the same or more powerful so that the welding machine does not overheat. To monitor the temperature of the inverter, you need to install a thermocouple.

But first you need to take care of the handle, which will make the welding machine from a computer power supply convenient to use. To do this, you need to remove all the spare parts from the power supply and attach a handle selected for size and convenience to the upper end. You need to drill holes in the power supply and secure it with screws, which must be correctly selected in length (too long ones will interfere with the internal circuit, which is unacceptable).

The welding machine must have very good cooling, so several additional holes need to be drilled in the power supply housing.

The duration of operation of a homemade inverter will depend on the quality of ventilation.

In the amateur radio environment, a single-cycle forward quasi-bridge converter, or in common parlance an “oblique” bridge, has become the main type of converter for constructing welding current sources. However, many industrial welding inverters, up to a load current of 250A (for example, ESAB Caddy Professional 250), use this circuitry. This work presents an attempt to make a small-sized and lightweight device for small welding jobs that do not require high current, which can be plugged into almost any outlet without fear for the safety of the wiring. The entire welder fits into the case of a computer power supply AT , a radiator from PIV , sawn into 3 parts, transistors are installed on two smaller parts IRG 4 PC 50 U , on the larger output diodes KD2997A. Transistors and output diodes are installed on radiators without gaskets! Everything is blown through with a fairly powerful fan Thermaltake A2016, 80x80mm, 0.48a, 4800 rpm, the fan has a built-in speed control depending on the temperature, the sensor is a thermocouple installed on the radiator of the output diodes. It was also necessary to drill additional holes in the case for better cooling, since the installation was quite tight and the existing holes on the front of the case were not enough. Overheating protection operates at approximately 70-72 degrees on the transistor radiators.

Despite the small size and weight of the PV it turned out quite as I liked

seems decent, about 100% at currents up to 80A, and at 100A already

you can cook passably with three...

Setting details can be found on the following websites:

You do not have access to download files from our server - Schematic and printed circuit boards

temperature was measured with a thermocouple from U T70A immediately after switching off,

the air temperature during testing was 22-24 degrees heating

the transformer is significantly smaller than the choke,

on the surface of the coil

the temperature did not exceed 55-60 degrees, hearts! 45-50 gr.

The cross-section of the inductor winding is better

raise to 10-12mm...

after shutting down due to overheating, it cools down for about 30 seconds,

then it turns on again...

Many summer residents and owners of private houses are faced with the need to perform welding work, for which they can use both purchased industrial installations and home-made welding inverters. If you have a high-quality diagram of such equipment and minimal experience with a soldering iron, making an inverter yourself will not be difficult.

If previously all welders were made exclusively on the basis of transformers, were distinguished by a bulky design, and their weight exceeded 50 kg or more, today inverters are popular, using fundamentally new technologies for converting electric current, which has made it possible to significantly reduce the dimensions of the equipment. Every homeowner who does not even have any serious experience with electronics will be able to make such a simple welding machine on their own.

An inverter welding unit is a modern, efficient technology that is based on the use of power switches and field-effect transistors. The Timval inverter combines compact dimensions, light weight and excellent quality welding current. Power is provided at a level of 200 Amps or more, which can also be used successfully on other refractory metals.

Thanks to high-quality power supplies, it is possible to carry out welding work even in conditions of significant power surges.

The inverter, regardless of fluctuations in the electric current at the input, will be able to efficiently convert electricity, and as a result we get a welding arc that is stable in its characteristics, which ensures a high-quality connection of metal elements.

Inverter characteristics

Self-made welding inverters of the “Barmaley” type may have the following characteristics:

• The input current is 32 A.
• The welding current is 160 A.
• Voltage consumption: 220 V.

On the Internet, you can easily select various circuits for an inverter welding machine with your own hands, which will differ in their power and the components used.

Tools and materials for creating an inverter

To construct such a unit, you will first need a high-quality inverter design. The simplest models will consist of the following components:

• Power unit.
• Power block.
• Power key drivers.

To do this work you The following materials will be required:

Making a power supply

You can either make your own power supply or use old parts from a computer or TV. In the latter case, this work is significantly simplified. If you plan to make such a power supply yourself, then you should remember that for an inverter it consists of four windings:

An electrical thyristor unit is also manufactured, which is necessary for the correct operation of the inverter. The thyristor unit can be purchased ready-made in radio electronics stores or made independently. Such a unit converts alternating current, which the inverter receives from the electrical network, into direct current, necessary for welding.

Remember that during operation the power supply and the power part of the inverter may heat up; accordingly, you will need to think about high-quality cooling of the device. To do this, we recommend using passive radiators from a computer, as well as simple coolers that effectively blow air over heating transformers. Such fans are simple in design, have an affordable price, and connecting them to the overall electrical circuit of the device is not difficult.

Purpose of the power unit

The supply voltage is supplied to the power unit, the main purpose of which is to reduce the voltage of the resulting current and simultaneously increase its strength. The easiest way to make such a power unit is from two cores, insulated from each other using newsprint. It is necessary to wind the cores for the manufacture of a transformer from copper strip, which will eliminate the appearance of interference and improve the overall quality of the welding current at the output of the device.

Making an inverter block

The main purpose of such an inverter unit is to convert electric current. If previously transformers were used for these purposes, which, in turn, led to Due to a significant increase in the dimensions of the entire structure, today power transistors are used that open and close the electrical circuit of the high-frequency converter.

The capacitors used in the electrical circuit of the inverter are connected in series and allow minimizing resonant surges and HDTV fluctuations at the output of the transformer. The capacitors used make it possible to reduce losses in the transistors of the power unit.

At first glance, the manufacture of such an inverter unit may seem like a difficult job that only professional radio electricians can do. However, in reality, if you have a high-quality welding machine circuit on hand, you can easily purchase the necessary capacitors and power transistors at a radio electronics store, and soldering on the board does not present any difficulty and takes at most half an hour.

How to assemble a welding inverter

First of all, you will need to make a housing for your self-made inverter. Some people use hand-made and welded metal boxes, while others use old, unnecessary computer cases for such equipment. On the front panel of such a welding inverter there should be terminals for connecting the cable and power supply, an on and off button, as well as a simple toggle switch for adjusting the power of the operating current indicators.

All completed pulse power units, power supply and cooling fans are connected to each other in full accordance with the existing circuit. The device body is insulated, after which the completed welding inverter can be tested.

Subsequently, a self-made inverter will not require any care or maintenance from you. Just do not forget about the need to clean the device every few months, for which you disassemble the case and remove the dust and dirt that has appeared inside.

Inverter welding, the implementation of which is not particularly complicated, is actively used in industry and everyday life. Making a homemade welding inverter is not particularly difficult. You just need to find a high-quality welding inverter circuit on the Internet, as well as purchase the required diodes, capacitors and power transformers.

A self-assembled welding inverter may not be as versatile in use and functionality as factory-made devices, but its cost will be at an affordable level, and the capabilities of such a device will be sufficient for using the inverter at home.

To ensure that welding work takes a minimum of time and effort, you need to ensure that you have an inverter that creates neat and invisible seams.

However, purchasing a new device is fraught with considerable waste, so you can make it yourself, using the means at hand.

If you buy a regulated power supply, then many problems fade into the background. But how to cope with the task on your own?

In order for the welding machine diagram to be as accurate as possible, you need to prepare the necessary spare parts and solutions that will enable you to transfer the boards to the required areas. You can make the work process easier by preparing special elements for working with such devices.

If you have an unnecessary power supply that was previously a computer one, then remove the main battery from it. Some people take an entire system unit, but to do this they need to increase the number of holes through which air enters.

The fan, case and spare parts are what you need to get out of the power supply. However, the final set depends only on the cooling modes in favor of which you have made your choice.

Don't forget to check if the fan is working. Install several of these elements to prevent overheating of the main elements of the device.

To control the temperature of the inverter, it is worth considering the presence of a thermocouple in it. Only in this case will the device serve you for as long as possible.

Make sure there is a handle in the design of the device, which will give you the opportunity to move it to the desired place without much effort. At the very beginning, remove all spare parts from the power supply, and then secure the selected handle.

Drill as many holes as you need in the power supply, and then secure the handle with screws or bolts. Be sure to ensure that their length matches the size of the power supply, otherwise they will touch the internal microcircuits.

So the inverter from the computer power supply is ready. If you do it right, you can save a lot of money.

Inverter advantages

You have understood the basics of creating a device. And now it is worth mentioning its advantages:

• the inverter weighs quite little, so the welding machine becomes lighter;
• Using this device you can save valuable electricity;
• the work process becomes easier and faster.

These are the main points that concern the inverter for the welding machine. Make a choice in favor of such equipment to independently evaluate all its advantages.

How to make a 12-220 converter from a computer power supply, watch the video:

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