DIY Battery Tab Resistance Fine-spot Welder

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Introduction: DIY Battery Tab Resistance Fine-spot Welder

About: During the development of the Maxun One solar bike, I constantly needed special equipment, parts and software, and so I rolled from one project to another. In September 2010, I started this website where I s...

A fine-spot welder is one of the few equipment where building yourself is cheaper than buying. There are already published a lot of DIY spot welders, this one has some unique features:

It can be used in 2 welding applications: opposed and series configuration.
The construction is kept very simple.
Accurate electrode force adjustment.
It has a solid electrode holder, made of a radiator earthing clamp.
An Arduino microcontroller is used to set the weld time accurately.
Creates a double pulse which improves clamping.
The current can be reduced for welding sensitive parts.

See more here:
http://www.avdweb.nl/tech-tips/spot-welder.html

1 Person Made This Project!

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29 Discussions

0
rajesh shelke
rajesh shelke

5 weeks ago

sir, can you share arduino program code complete from start to endfor battery weld controller.mymail id is :-teknossr@yahoo.com i am stuck up with this project using encoder switch ,oled &arduino uno

0
mjohnson82
mjohnson82

1 year ago

I purchased the new board it came with 7.1 software. I want to upgrade to the 7.2 software. I have it in arduino ide and have a usbasp 10 pin programer what is the pin out for the straight ftdi connector on the board?

0
avandalen
avandalen

Reply 1 year ago

see the circuit on the website

0
mjohnson82
mjohnson82

1 year ago

How do you calculate the resistance to reduce current. my 1100 watt transformer with 4 turns burns through battery the primary measures .7 ohms. 270 ohms in the schematic is too high with not enough current to weld.

0
avandalen
avandalen

Reply 1 year ago

You cant use a resistor, just reduce the weld time or increase the weld pin force.
Or use the new software version 7.2

0
BenKeith
BenKeith

3 years ago

A word of advise. Order his ATmega328 with his software already loaded on it. I just spent almost two day's getting a blank, $3 ATmega328-PU loaded with the required software. If you a fairly competent with Arduino, you might bet a blank chip setup. If you are not good with Arduino, you definitely want to order his unless you are planning on using the Arduino UNO and just build the power supply section. Even then, just getting all the software required loaded into the Arduino board is a royal pain. Definitely not worth the few dollars you might save. Understand also, some of those cheap, fake boards out of China don't have the bootloader in them and may cause you problems.

0
Southerner
Southerner

Reply 1 year ago

Blank ATMega328's will require that the bootloader be loaded first as they do not come with that preprogrammed...unless you buy them that way. Blank ATMega328's are about $2 each but if they have the bootloader preloaded they are about $4 each.

0
Southerner
Southerner

3 years ago

What size and type wire is used to make the new secondary on the microwave oven transformer? How thick is the insulation? Can motor rewind wire be used? It is square or round copper wire with a varnish on it. Other articles I have read about modifying microwave oven transformers give a general rule of thumb of about 1 volt per turn on the new secondary.

0
mjohnson82
mjohnson82

Reply 1 year ago

I used a 1100 watt microwave transformer with 4 turns of #2 gauge My open circuit voltage is 4.1 on the lowest time of 200 us I burn through the battery

0
avandalen
avandalen

Reply 2 years ago

Use official weld cable, that is perfect.

0
cuny-ravet
cuny-ravet

Question 1 year ago on Introduction

bonjour,

j'ai bien reçu la carte de soudeuse ; pourriez vous me communiquer le shema de branchement

merci d'avance

0
hoospiders
hoospiders

2 years ago

albert,

i ordered your pcb almost two years ago to the day (4/22/16) and never got around to building the spot welder. well, it seems that you have been busy since then, and now have an updated version that you sell pre-assembled. question: can the time for pre-weld, pause, and weld be set via push-buttons using the spot welder based on the "original" pbc, or should i just order the updated one from you? let me (us) know, and thanks for sharing.

vince

0
hoospiders
hoospiders

Reply 2 years ago

thanks for the reminder re: the push-buttons. i am currently populating the pcb with components.

i realized that your .xls mouser shopping list shows (1) as the quantity for mouser part # 538-08-50-0185. i think it should be (2) as wire housing part # 538-10-11-2023 is 2-position.

i ordered the following tft from amazon, same price as ebay:

https://www.amazon.com/gp/product/B00LSG5HI0/ref=o...

and this foot pedal as well:

https://www.amazon.com/gp/product/B00K81AG0U/ref=o...

0
avandalen
avandalen

Reply 2 years ago

The old version has the same menu control as the new smd pcb version.

0
UA_Stuka
UA_Stuka

2 years ago

Hi! Just got the controller board from you. Building the welder now. Can you please tell me what were the settings you used to weld tinned copper wire to the 18650 battery tab?

0
avandalen
avandalen

Reply 2 years ago

I never used tinned copper, copper is hard to weld because it has too low resistance to get heated by the weld current.

0
asvybre
asvybre

2 years ago

Very good work on this project! Although I am not convinced yet, I have only seen one pic of a weld done with the machine and it showed some discoloration. If the maker or either anyone who have done this could provide one example I would be very grateful.

Thank you!

0
Burgrc8b
Burgrc8b

2 years ago

What would cause the transformer to burn up as soon as unit plugged in?
In US- so using 110v. Also, my transformer is- AVB 2,0/2/9
I check all my other components against your pictures and everything else looks exactly the same. I did not cut the 2 inside terminals on this transformer because I didn't think it was necessary. Could that be why it happened? Once again, as soon as I plugged it in- poof. I didn't touch any switches at all. The LED lit for a second and then transformer went.
Also, is there a way to test before I waste another transformer?
I have spent a lot of time on this. Please help me when you get time.
All I wanna do is weld these 4000 batteries I have. Please!!!???

0
avandalen
avandalen

Reply 2 years ago

I think te transformer is mounted reversed, so primairy windings to mains. Please sent a picture of the board.

0
AndreasP25
AndreasP25

3 years ago

I have built this eventually, the problem I am having is, on the timmer settings 1 to 3 the spots look good but they haven't welded, on 4 an above its too powerful and has burn marks on the tabs. the transformwer says 700e on it, is this transformer too small?