Author Topic: kWeld - "Next level" DIY battery spot welder  (Read 47640 times)

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Offline Fraser

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Online tautech

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Re: low cost DIY battery spot welder [guesses on ... - solved]
« Reply #126 on: July 17, 2017, 05:32:47 PM »
hmmmm. Fraser that's very interesting, but I'm not sure if you have understood me correctly. I haven't added flux between battery and tab, but between tab and electrode.
What was your rationale for doing this ?  :-//
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Offline tatus1969

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Re: low cost DIY battery spot welder [guesses on ... - solved]
« Reply #127 on: July 17, 2017, 06:22:53 PM »
What was your rationale for doing this ?  :-//
curiosity. to see if that helps reducing coloring. it does 8)

This article caught my eye. How to check what strip material you have been sold ...... pure nickel or the cheaper plated steel.

http://www.ebikeschool.com/how-to-differ-between-pure-nickel-strip-battery-tabs-vs-steel-core/
I can make another proposal: measure up a reasonable length of your strip material, press the electrodes of my welder against the ends of that, trigger a pulse of lets say 50J, and take the ohmic resistance that it reports to determine the material  ;)
« Last Edit: July 17, 2017, 06:27:41 PM by tatus1969 »
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Online tautech

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Re: low cost DIY battery spot welder [guesses on ... - solved]
« Reply #128 on: July 17, 2017, 07:07:07 PM »
What was your rationale for doing this ?  :-//
curiosity. to see if that helps reducing coloring. it does 8)
In my mind it's just acting as a coolant then so other liquids could have the same result........could you try some others to further satisfy curiosity ?
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Offline tatus1969

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Re: low cost DIY battery spot welder [guesses on ... - solved]
« Reply #129 on: July 18, 2017, 12:16:12 AM »
What was your rationale for doing this ?  :-//
curiosity. to see if that helps reducing coloring. it does 8)
In my mind it's just acting as a coolant then so other liquids could have the same result........could you try some others to further satisfy curiosity ?
I'm a bit hesitant to use other liquids like water, because I am afraid of eruptive vaporization. It is just that advantage which flux has that it just crumples instead.
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Offline negativ3

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Re: low cost DIY battery spot welder [guesses on ... - solved]
« Reply #130 on: July 18, 2017, 01:42:22 AM »
Please let us know when Paypal is ready to use.
 

Offline tatus1969

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Re: low cost DIY battery spot welder [guesses on ... - solved]
« Reply #131 on: July 18, 2017, 01:45:01 AM »
Please let us know when Paypal is ready to use.
I had them on the phone last Saturday, they told me that unlocking it for businesses is a manual process and that I will have to wait for one to two weeks  |O I will definitely keep you updated, and notify you immediately.
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Online Kjelt

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #132 on: July 18, 2017, 04:31:26 AM »
Oops did we have to wait with the pre-order? I am confused  :-//
 

Offline Fraser

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #133 on: July 18, 2017, 04:57:25 AM »
From what I understand,

Pre order is fine if you do not mind using the 'Stripe' secure credit card payment system. The delay relates to Frank getting his PayPal approved for accepting payments via the web page.

Fraser
 

Online Kjelt

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #134 on: July 18, 2017, 05:05:52 AM »
Ok good to hear  :-+ , problem is more that credit card transactions cost the seller more than a paypal transfer.
 

Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #135 on: July 18, 2017, 06:18:53 AM »
From what I understand,

Pre order is fine if you do not mind using the 'Stripe' secure credit card payment system. The delay relates to Frank getting his PayPal approved for accepting payments via the web page.

Fraser
Thanks for answering this for me  :)

Ok good to hear  :-+ , problem is more that credit card transactions cost the seller more than a paypal transfer.
That appears not to be the case here. Paypal charges more than Stripe... Anyway, they both charge something, but that is my duty  ;)
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Online Kjelt

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #136 on: July 18, 2017, 06:50:23 AM »
Good to hear now I don't feel guilty  :)
 

Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #137 on: July 18, 2017, 06:54:41 AM »
Good to hear now I don't feel guilty  :)
Companies like Visa and Paypal should feel guilty, not you!
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Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #138 on: July 18, 2017, 06:57:18 AM »
It was again exaggerated complexity that kept me from getting where I want. There is Paypal, Paypal Express, Paypal PLUS, then they tell you something about different APIs, bank account authorization, and so on. To summarize this: Paypal is now available in the shop, it was again easier/quicker than expected!
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Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #139 on: July 18, 2017, 07:33:06 AM »
I wasn't happy with the lifetime of my regular Turnigy 3S/5Ah/50C packs. I know that my usage profile for welding with them was far from daily life duty, I think during my abuse test with the cookie can it was more or less 50% duty cycle at 1kA. I have ruined two packs until they both showed noticable swell. They are still usable, and pulse current is still at 900A, but I am aware that this literally playing with fire, and I wouldn't copying this to anyone.

Hence, I decided to order one of these, and make a test under "realistic" usage conditions for welding:

https://hobbyking.com/media/catalog/product/cache/3/image/565x414/9df78eab33525d08d6e5fb8d27136e95/1/7/175937_9210000231-0.jpg

These are rated at 130C (pulse), which is 650A (!). Let's see what they will deliver in practice.
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Offline DBecker

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #140 on: July 18, 2017, 01:11:17 PM »
I expect that the flux is primarily excluding atmospheric gases as the weld cools, preventing discoloring.  You might compare the effect to mineral oil and brake fluid.

 
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Offline maukka

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #141 on: July 18, 2017, 06:11:03 PM »
I went with a Turnigy Graphene 6000mAh 5S1P 65 battery. According to Mooch they seem to be the best performers in high current applications (low internal resistance).
 

Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #142 on: July 18, 2017, 06:45:41 PM »
I went with a Turnigy Graphene 6000mAh 5S1P 65 battery. According to Mooch they seem to be the best performers in high current applications (low internal resistance).
That is what I also ordered, but 5Ah/3S. Will be interesting to see my system running at 5S, that is still on my to do list.
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Offline BFX

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #143 on: July 19, 2017, 03:32:12 AM »
Did you try power up your Gerät by MOT? For users which refuse buy an battery?  :box:
 

Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #144 on: July 19, 2017, 03:49:06 AM »
Did you try power up your Gerät by MOT? For users which refuse buy an battery?  :box:
That'll not work easily because the module expects DC, the power switch is not bidirectional. One would need to add a diode with at 1000A pulse rating at the input, but that would also require a firmware extension that synchronizes firing with the rectified waveform.

The options that I can recommend at this time are a capable enough Lipo battery [that still has to be evaluated], a good car battery, and a suitable ultra capacitor.
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Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #145 on: July 21, 2017, 12:28:14 AM »
All the parts and tools for the new electrode system have arrived now. I will make a first complete build with video, but the first critical question is already answered: does the cable crimp work? See this picture of a cross section  :-+





« Last Edit: July 21, 2017, 12:34:18 AM by tatus1969 »
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Online Kjelt

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #146 on: July 21, 2017, 01:32:10 AM »
 :-+ that looks as it is supposed to be, contact me please before shipping as it now looks like this crimp connection and new electrode system are really what I would like.
 

Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #147 on: July 21, 2017, 04:06:37 AM »
:-+ that looks as it is supposed to be, contact me please before shipping as it now looks like this crimp connection and new electrode system are really what I would like.
If you like to change, or cancel and redo your order, please just give me a note. I can refund you whathever the difference is, and you don't need to worry about having to pay double shipping.

Cheers
Frank
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Offline tatus1969

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #148 on: July 21, 2017, 04:17:50 AM »
Here are pictures from the first build of the new electrode arrangement. The clamping mechanism works very well. I have done some welds with it, and it develops less heat than the previous design. I'll keep it like that and this is (or the parts for it) is what will be delivered when ordering it from the shop.





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Offline Fraser

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Re: kWeld - "Next level" DIY battery spot welder
« Reply #149 on: July 21, 2017, 08:47:07 AM »
I decide that a simple hydraulic crimping tool would be useful to have in my tools collection so I have bought one this evening.
It is likely not that great for serious work but should meet my needs and those of this project. I also intend to use it as a mini hydraulic press once I have made up some flat face 'dies'.

There are two very similar looking versions on eBay. One is rated at 8T, whilst the other has a stronger head and is rated at 10T. The 8T comes with 8 dies and the 10T comes with 9 dies. I went for the 10T version.

The cost is £21.99 delivered from a UK warehouse. They are cheaper direct from China but I did not want to wait.

http://www.ebay.co.uk/itm/10-Ton-Hydraulic-Crimper-Crimping-Tool-Wire-Battery-Cable-Lug-Terminal-9-Dies-/322502047411?epid=1944118370&hash=item4b169eb6b3:g:LWEAAOSwT-FZCFV2

Fraser
« Last Edit: July 21, 2017, 09:11:07 AM by Fraser »
 


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