Well thats a first! Thank you, we do use TC junctions around here (I havent used one so far) and when I asked, I was told we dont have a TC junction welder. Even the smallest misalignment in the workpieces can cause major issues. Batteries are a necessary evil in todays world of portable everything. Yes I agree that the discussion of self-bricking with the red BMS and others was good but that was only a few minutes out of the video. The controller permanently shutting down is a safety feature in this case. Holding a part with both hands, you can initiate the weld with a shrouded foot switch. running it from a lead acid might also have something to do with it. Batteries are horrible. Electric shock. This has electrodes that are attached to long cables so they can reach inaccessible places. I cant get past the first minute. Commercial welders often deliver two or more pulses, which in turn resistively heat the metals to be welded. Safety glasses are a must. Linus, The cells you bought are crap. Branson Ultraweld L20 Spot Welder. Basically, this is clickbait and uninformative as is. If this method is not practical, the pinch-point safety device should provide you with the required protection. Apparently its fixable: https://www.karosium.com/2016/08/hacking-bq8030-with-sanyo-firmware.html. Warping and a loss of fatigue strength can occur around the point where metal has been spot welded. 2.) Also in the box was a piece of paper advising on the type of batteries suitable for the task, which boil down to something close to a car battery. Experiment with a combination of timings, starting at the shorter durations, and gradually building up to longer ones. They should have purchased a nice Kweld-unit, its 10000 times better for sure. Fortunately, these BMS chips all have configuration tools and software that can be used to reset permanent failures, so for someone with the know-how, these protections are not an impediment to replacing the cells. Now when I cant find a source for a dead battery pack, Im often able to remove the old batteries and weld in new batteries and foils, or even make up a whole new battery pack from scratch. Easily access valuable industry resources now with full access to the digital edition of The Tube & Pipe Journal. After that the State paid for his schooling so he could teach what he knew. Otherwise theres a power setting calibrated in E, with no explanation as to what an E is. Along with the unit was a set of leads, the welding leads being terminated in a set of insulated except for their tip copper probes and the battery leads being unterminated. If you are not Starting at 5E and setting out to find the point at which the device would do a successful spot weld, I increased the power in steps of 5E and tried a weld at each level. CO2 Welding Metal arc welding in which the consumable electrode is fed into the arc at a constant speed with a high current density, any alteration in arc length being corrected by naturally occurring changes in the burn-off rate. If the current is not strong enough, hot enough or the metal is not held together with enough force, the spot weld may be small or weak. But it may not have been the primary motivation. Linus Tech Tips annoys me on many levels. Im not arguing your point, just writing what I wouldve done. When making battery packs, I do it in a dedicated space either outdoors or in a garage well away from anything that could short circuit the batteries and cause them to catch fire. Spot welding is quick and easy and creates a strong join. Watch Out SiC, Diamond Power Semiconductors Are Coming For You! No-name, bought off Amazon, same form factor so probably a similar design: Dont forget to include a flyback diode (google this) across the output circuit of the solenoid so as to absorb the kickback from the coil of the solenoid. When you test your project, wear rubber gloves and rubber soled shoes and work in a dry, well lit environment. The metal may also become less resistant to corrosion. Also some work but wont last more than 20% compared to the original batteries or probably fail in 2-3 months. The problem is that this is a small volume product. It's a straightforward process, but there are many ways that things can go wrong if you don't have spot welding experience. From: Smithells Metals Reference Book (Eighth Edition), 2004 View all Topics Add to Mendeley About this page Welding Zineddine Haboussi liked Flexible Analog Computer. Spot Welder is a simple device that uses high current to produce heat and focus it on metal pieces to join them. Christian MARTINEZ has updated the project titled BME280 and DWIN for smart monitoring. . Red has followed the same business model as their legacy competitors; lock people into the system and make lots of money selling the extra bits and pieces they need. I am going to switch to a capacitor Bank with a dc power brick. If you tend to weld outside or "in the field" a pair of sunglasses under your hood can also work well. It is a PAIN to watch him bin one set of cells after another. 2023 Leaf Group Ltd. / Leaf Group Media, All Rights Reserved. Reaching for a small bench vice, I was able to position them both such that I could hold cell and strip together against their tips and operate the welder via the foot switch. This design is super safe - supplied from 5V DC, output voltage no higher than 30V DC. By using our website and services, you expressly agree to the placement of our performance, functionality and advertising cookies. I keep my metal tools outside the rails of the dedicated work space, and always set a metal tool down outside the work space when Im momentarily done with it. Dual palm buttons connected to an anti-tie down and antirepeat circuit have long been the standard initiation method used for projection welding machines. Figure 1 yOyOeK1 has updated the project titled oiyshTerminal. Modern spot welding therefore uses 2 pulses: the first one causes the metals to heat up a little, raising their resistance, and the 2nd pulse delivers enough energy to weld the heated spot. Adam Welch shows it in a video titled Repair Attempt. They did a good job of showing how hard it is for an average person to attack this problem. Methane-Tracking Satellites Hunt For Nasty Greenhouse Gas Emissions, ChatGPT V. The Legal System: Why Trusting ChatGPT Gets You Sanctioned, Chatting About The State Of Hacker-Friendly AR Gear, Hackaday Podcast 221: The Future Of The Raspberry Pi, Sniffing A Toothbrush, Your Tactical Tool Threshold, Hackaday Prize 2023: This Challenge Makes It So Easy Being Green, AI Camera Imagines A Photo Of What You Point It At, Flexible Actuator Flaps For 100,000,000 Cycles Without Failure. Commodore 64 Web Server Brings 8-Bit Into The Future, Hackaday Prize 2023: Building A Relay ALU. The electrodes have to be able to reach both sides of the pieces of metal that are being joined together. Nothing to worry about here. For example, a typical spot welding tip with a -inch-diameter weld face used in conjunction with 600 lbs. Eric Bagai is a senior writer in the high-technology field, to which he can offer more than seven years of experience as a copywriter. The cheap type have severely limited power. So in their case the internet probably was to be evil above all else. Overall we found the video informative, and we hope you do too. The technique involves the application of immense pressure, heat, and electrical current through the metal sheets. Unfortunately a lot of ltt and other media seems exactly like this, despite whatever image they are presenting. Our goal is to make science relevant and fun for everyone. Using 12 winds on the transformer (at about 1 volt per winding) gives you 12 volts, power is proportional to the square of voltage, and adjust the pulse width as needed. I wonder if this one, or any similar device can also be used for welding thermocouple wires together? I was thinking of doing this but seeing how it might be more difficult than I thought I wont be trying this. This will eventually destroy the batteries. This is a common practice to prevent people to not buying new products, remeber the economy moves by capitailsm model, and if you not buy, then money doesnt move. The machines used in car factories produce as many as 200 spot welds in six seconds. i.e. User error. Welding energy adjusted by the Variac. Spot welding machines are available in two basic stylesrocker arm and vertical-action press-type machines. It works acceptably well on AA/18650 size cells. Per the Bureau of Labor Statistics, . Answer (1 of 54): I would like to add an answer to this question, "What is the most dangerous part of being a welder?" The reason for this is my dad worked as a welder till I was about 13 when his back went out on him. The two pieces of metal are pressed together with electrodes on either side. NEVER used, never recharged. Using somebody elses battery can be nice but for that to be workable you really need there to be a suitably mass-produced battery that meets your electronic requirements AND you can be sure will still be there for the entire lifespan you wish to support your product. The handle of large needle-nosed pliers are connected to one cap terminal, and a copper plate is connected to the other cap terminal. I use a large DC source, a switch, and a large electrolytic capacitor. Most people are already aware of DRM protections, especially those of us surfing Digikey and designing our own. With a love of putting the cheaper end of the global electronic marketplace through its paces for the entertainment of Hackaday readers I couldnt resist, so I parted with 15 (about $20), for a Mini Spot Welder, and sat down to wait for the mailman to bring me the usual anonymous grey package. The join forms only at the spot where the electrodes are in contact with the metal. Not to mention they equalised the cells to start with, so short of shorting out the pack, the only source for the sparks could be welder. I was considering one of these after watching an effusively positive video, glad I waited and thank you for your service. Commercial battery spot welders do a good job but have a huge inrush current and arent cheap, so its not uncommon to see improvised solutions such as rewound transformers taken out of microwave ovens. LTT went with the high end choice because they could afford to, because their photography guy wanted to, and because theyre making enough money to afford to do it. There are some control buttons and a power switch on the board along with a socket for a foot pedal, and the main board has screw terminals, a row of hefty MOSFETs, and a large electrolytic capacitor. I think its fair to say this specific instance of this model and perhaps even this specific model as a whole was a fail, but to extend that to say all cheap battery spot welders dont deliver is stretching it a little thin. Therefore, just like dealing with a loaded gun, operator training and a culture that encourages safety first should be a top priority. It wasnt until a friend of mine showed me his cheap spot welder and was successfully using it that I realized what the difference was. They churn out content for money, even if they think theyre doing good.. I use a plastic nonconductive table top, with plastic rails that enclose and define the work space only for the battery pack under construction. Admittedly theyre not targeting the cinematic market; their products rarely show up in the production of theatrical films or high-end TV shows, whereas Red cameras sometimes do. When Battery Rebuilds Go Wrong: Understanding BMSs, Spot Welders, And Safety. If you are not careful, it will deliver that same force to your hand or finger (see Figure 1). Thingiverse already has a 3D battery holder with swappable components to fit various tool systems, some assembly required. checkyourshipment has added a new project titled Check Your Shipment. And they failed to properly identify the risks or troubleshoot a process that they perceived to have been conducted in an unsafe manner. Methane-Tracking Satellites Hunt For Nasty Greenhouse Gas Emissions, ChatGPT V. The Legal System: Why Trusting ChatGPT Gets You Sanctioned. Jep ive got a few of those. Its common with small batteries for backup memories like old pre-flash memory cards and suicide batteries in arcade systems, but quite dangerous with large lithium packs. Just add your cells, regulation circuitry, and contact tabs. They are very short 10 gauge wire. Do you have a link to the newer design with the cap or the older version and the fix thats needed? That reply had information on everything I was curious about after reading the write-up. Usually, welders are prone to a lung infection that can lead to fatal pneumonia. \$\endgroup\$ - Mike Waters. Typically, when you accidentally touch the leads or piece of metal across you are often left with two big chunks of metal missing from where they made contact. The fix seems simple add a cap so the voltage to the switching electronics is maintained. There are a large number of these mini spot welders, some have issues that need to be corrected. Why not just solder the wires to the batteries? The welder wants to achieve "as little spark as possible," he said. Get a trickle charger so you can keep your battery in good shape. The size and shapes of the electrodes will determine the size and strength of the weld. https://www.amazon.com/Handhold-YaeCCC-Battery-Current-Display/dp/B07CV68VZD. It is wound with three rounds of thick copper wires. A capacitor added. If it was primarily that, Id be less annoyed. Mechanical Hazards: Add to this that you cant extinguish a Lithium battery fire with anything, so it becomes mandatory to avoid the cells any stress that could make them destabilize, like heat and electrical/physical damage. Also, sharpen the electrodes to a dull point (not a sharp point) for better welds, but its a trade-off with the point resistance noted above. This site uses Akismet to reduce spam. The same maybe true with the failsafe in this particular instance, but they definitely have a point about the dark side of BMSs from certain manufacturers. Still do not understand why you cannot solder those batteries. Easily access valuable industry resources now with full access to the digital edition of The FABRICATOR. Or Price? The intense heat and light from arc welding can be dangerous. Spot welding parameters are referred too as the "welding circle" as there are four settings, Power, Pressure, Electrode and Time. This spot welder board works really well. It took absolutely forever (almost four months!) Welding is an activity that is considered dangerous, so read up on the resources we provide below, do your own research, and most importantly, . Spot Welding Hazards and Safety January 19, 2019 by Mahnoor There are many hazards produce while performing experiment on Spot Welding Machine.While using this machine we must know its Hazards,Risks and Control for safety about Spot Welding Machine. Due to the excessive force used in resistance welding, welders can inflict bruises on themselves if they are careless near the electrodes. 1. There is no need to use any fluxes or filler metal to create a join by spot welding, and there is no dangerous open flame. Personally I think at the step down transformer based spot welders with the copper jaw electrodes are a good way to go (although probably wont work for tacking nickel electrodes to 18650s and 21700s). Spot welding can be used to join many different metals, and can join different types to each other. its mandatory to make people think that!!! I rebuild a NiMh pack with 12 batteries, ie. Recent research by HSE found that welding fumes can overwhelmingly cause asthma. It was a model with LiIon battery included, a bit more expansive, but the core design is the same. In the first part, (LTT an experienced expert tech engineer internet guru guy), he shows stupidly and sarcastically how to repair a battery with new cells like an amateur guy. This causes the drain of the mosfet to close and open, which applies a small current to the input of a motorcycle solenoid. Our welders were pretty simple. Its not a tamper-resistance feature. Actually, these cheap spot welders have come a long way over the past couple of years. I first tried to hold the two probes in one hand and apply them to strip and cell with the other, but found I lacked the dexterity to pull this off. Welding is one of the most dangerous tasks for workers in industrial settings. Correction found the: You bought Email: I bought them over 8 years ago (jan 5 2014). February 16, 2022. decided to take battery repair into his own hands. Theres another possibility though, in the form of cheap modules that promise the same results using a battery pack as a power supply. Soldering requires much lower temperatures, i.e., 450 degrees Celsius or 840 degrees Fahrenheit. He had the same issue and had to repair a blown mosfet, but he also applied a fix to the unit from Maker Fabio https://www.youtube.com/watch?v=fdnO0Z-scjA after that it worked. In reality, if sparks are flying from a squeeze-type resistance spot weld, "that means it's not good," according to Dorn. In certain industries, there is more or less standard batteries. I had a suitable sealed lead-acid battery to hand as well as a few dubious 18650 cells of the extremely lightweight obvious fake variety, so taking a short piece of nickel strip I set out to weld cell and strip together. Retraction, sometimes called high lift, makes it easier to load 3-D parts, such as those with flanges or lips, into the throat before welding. Install it all in an enclosure (I used a cheap ammo can box from Walmart). However, few plants can afford that luxury and today most spot welders are still manually operated. Please be kind and respectful to help make the comments section excellent. So when using these cheap welding machines, it takes a little practice, but what you have to do is touch, not push, touch the leads to your nickel strips, just enough so that the nickel make a weak contact to the battery and the result is enough resistance and the sudden rush of massive amps going from contact lead down through both the nickel strip and the battery and up to the other lead welding both sides.
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