Introduction: Einhell XChange - Soldering Iron
I always wanted a transportable soldering station. After a cheap gas-soldering iron caught fire, I was looking for soldering stations with a rechargeable battery. The ones I found weren’t that cheap or didn’t fit my needs, so it was time to design one by myself.
This project includes:
- 3D-printed parts
- Laser-cut metal parts
- Hot glue
- Sensor cable 4x0,34 mm² (approx. 1 m)
- Flat male crimp contacts 4,8 mm (2 pieces)
- DC soldering iron (can be found on Aliexpress)
- DC Jack connector
- M3 nuts and bolts
Step 1: The Einhell XChange System
Due to the reason that I already had an Einhell jigsaw I wanted to design a soldering station that fits on the Einhell xChange system.
The fact that Einhell offers a lot of tools on the cheaper side for their xChange battery-packs supported my decision, because I suspected that the whole intelligence must be in the battery-pack to produce the corresponding tools cheaply.
To prove my suspicion, I opened the jigsaw and found a very basic electrical circuit.
Everything was directly connected to the battery.
The “switch-unit”, which also regulates the motor speed, needs a MOSFET for operation, but that shouldn’t be something to think of, when designing the soldering station.
Step 2: Assumptions
The battery-pack has a rating of 18 V and 3 Ah, which equals a total energy of 54 Wh.
If a 65 W soldering iron would be used, it could run for about 50 minutes at 100 % power (which is not totally correct, but in this case, the calculation fits the needs).
A 65 W soldering iron draws a current of 3,6 A at 18 V.
Step 3: The Electrical Design
The electrical design is quite trivial, because the whole brain is in the battery-pack and a soldering iron which works from 12-24 VDC is used.
Step 4: The Mechanical Design
Due to the reason, the station should be transportable, the design had to be as compact as it could be.
Also, the 3D-printed components should be reduced to an absolute minimum. I decided to design and print a top and bottom part. Between the 3D-printed parts there’s space for a PCB.
And aluminum-holder was designed and laser-cutted for the soldering iron.
Step 5: Assembly
Step 6: Final Thing
After two hours of assembling the soldering station turned out pretty fine, I think.
Also attached are the assembly STL-files.