DIY Battery Spot Welder Using An Old Microwave & Arduino

DIY Battery Spot Welder Using An Old Microwave & Arduino

Spot welding is a type of welding that uses a high-current, low-voltage pulse to create a weld joint between two pieces of metal. It is commonly used to weld battery packs, as it does not require any filler metal and creates a strong, reliable weld.

Building your own spot welder can be a fun and rewarding project, and it is a great way to save money on the cost of buying a commercial spot welder. In this tutorial, we will show you how to build a simple but effective battery spot welder using an old microwave and an Arduino microcontroller.

Materials:

• Old microwave
• Arduino microcontroller
• Solid state relay module
• Potentiometer
• Seven-segment LED module
• Red button switch
• Wire
• Electrical tape
• Wood or other material for enclosure

Tools:

• Screwdriver
• Wire strippers
• Soldering iron
• Drill
• Saw

Instructions:

1. Remove the transformer from the microwave. Be careful not to cut yourself on the sharp edges of the metal.
2. Cut open the transformer to expose the coils within. Be careful not to damage the coils.
3. Replace the smaller coil with an even smaller one made from six-gauge wire. This will allow the transformer to handle the extremely high current needed for spot welding.
4. Reassemble the transformer and mount it to a wooden or other sturdy base.
5. Connect the transformer to the Arduino microcontroller using the solid state relay module.
6. Connect the potentiometer to the Arduino microcontroller. This will allow you to adjust the pulse length of the spot welder.
7. Connect the seven-segment LED module to the Arduino microcontroller. This will display the pulse length of the spot welder.
8. Connect the red button switch to the Arduino microcontroller. This will be used to trigger the spot welder.
9. Enclose the spot welder in a wooden or other non-conductive material. This is important for safety reasons.

Once the spot welder is assembled, you can use it to weld battery packs by following these steps:

1. Place the battery cells in the desired position.
2. Place the spot welder electrodes on the battery cells.
3. Press the red button to trigger the spot welder.
4. Hold the electrodes in place for the duration of the pulse.
5. Release the red button and remove the electrodes.

Repeat steps 3-5 for each weld joint.

Tips:

• Use copper electrodes for the best results.
• Make sure the battery cells are clean and free of corrosion before welding.
• Use a pulse length that is appropriate for the thickness of the battery cells you are welding.
• Be careful not to overheat the battery cells, as this can damage them.

Safety:

• Spot welding is a dangerous activity, and it is important to take all necessary safety precautions.
• Always wear safety glasses when spot welding.
• Be careful not to touch the live electrodes, as this can cause a severe electrical shock.
• Make sure the spot welder is properly enclosed to prevent accidental contact with the live components.

Conclusion

Building your own battery spot welder is a great way to save money and get a custom spot welder that meets your specific needs. By following the steps in this tutorial, you can build a simple but effective spot welder using an old microwave and an Arduino microcontroller.