Affordable spot welder for huge packs

rg12

100 kW
Joined
Jul 26, 2014
Messages
1,584
Hey guys,

I'm looking for a pneumatic spot welder that can go very "deep" into the pack as I'm doing many 20S 18P packs
The spot welder head needs to go about 9-10 cells "deep"

I prefer it as one unit as the separated units with huge copper cables to the welding unit need much more current and trip the switch almost everywhere I tried.
 
https://malectrics.eu/product/diy-arduino-battery-spot-welder-prebuilt-kit-v3/

only needs a car battery and if you make your own cables from 16mil you can use 1M long cables.
i use this and have the unit and battery above the work area on a little shelf. i can weld basicaly up to 1.5M wide packs in a single go.
 
I got something like this but I need a professional machine with air pressure driving the head to push down at the tab
 
rg12 said:
I got something like this but I need a professional machine with air pressure driving the head to push down at the tab

You can buy those from a few companies. I have contacted a couple in the past for this but pricing was not worth it. You are looking at 2k and up for the whole machine and 700+ for a single head assembly. Shipping and taxes added another 500 or so.

Right now i am just looking into something to cut the nickel to length for me. That takes up most of my time and causes hand strain so i likr to spend money there first.
 
How about something like this


https://www.ebay.com/itm/Y-Type-Nickel-Conductive-Plate-0-15-6-25-Mm-For-18650-Battery-500-Pieces-Lot/332674080886?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D52473%26meid%3Dc255cb66742f4a8c8509feb98f175a19%26pid%3D100005%26rk%3D5%26rkt%3D5%26sd%3D252952906089%26itm%3D332674080886&_trksid=p2047675.c100005.m1851

https://www.aliexpress.com/item/500pcs-0-2x30x8mm-H-type-Nickel-Plated-Steel-Strap-Strip-Sheets-for-battery-spot-welding-machine/32352134818.html?spm=2114.search0104.3.127.81ff14a6Oa2W44&ws_ab_test=searchweb0_0,searchweb201602_3_10152_10151_10065_10344_10068_10547_10342_10343_10340_10548_10341_10696_10084_10083_10618_10304_10307_10820_10821_10302_10059_306_100031_10103_10624_10623_10622_10621_10620,searchweb201603_30,ppcSwitch_5&algo_expid=0b57418a-bc4c-439c-8da5-285f8f22ac9a-18&algo_pvid=0b57418a-bc4c-439c-8da5-285f8f22ac9a&transAbTest=ae803_2&priceBeautifyAB=0
 
flippy said:
rg12 said:
I got something like this but I need a professional machine with air pressure driving the head to push down at the tab

You can buy those from a few companies. I have contacted a couple in the past for this but pricing was not worth it. You are looking at 2k and up for the whole machine and 700+ for a single head assembly. Shipping and taxes added another 500 or so.

Right now i am just looking into something to cut the nickel to length for me. That takes up most of my time and causes hand strain so i likr to spend money there first.

There you go:
https://www.aliexpress.com/item/Aut...c60d-49ab-a83b-a9a407213c17&priceBeautifyAB=0


As for me I guess I will go with this one and extend the head with longer CNC'd copper nose:
https://www.aliexpress.com/item/1pc...2b3d-4d5b-8992-49cd0ec1243a&priceBeautifyAB=0
 
flippy said:
https://malectrics.eu/product/diy-arduino-battery-spot-welder-prebuilt-kit-v3/
only needs a car battery and if you make your own cables from 16mil you can use 1M long cables.
i use this and have the unit and battery above the work area on a little shelf. i can weld basicaly up to 1.5M wide packs in a single go.

Thanks a lot for the link! The full bundle (missing just the car battery) costs only €118,80 shipping to Russia included!!! Just googled and found that a 60Ah/530CCA battery costs €46 in my city. It would be more than enough. So the total cost is €165 (or less) for an off-grid spot welder! I'm don't know if there are any cheaper off-grid battery-powered options but this one looks very good to me! Thanks again!
 
Making the cables longer than one meter (1/2M each, 1M total combined length) can add significant inductance to the system.

I think it's possible to attach the spot-welder onto an elevated "table" that allows the battery pack to slide under it. Doing that not only keeps you from needing longer cables, they can then be VERY short.
 
spinningmagnets said:
Making the cables longer than one meter (1/2M each, 1M total combined length) can add significant inductance to the system.

I think it's possible to attach the spot-welder onto an elevated "table" that allows the battery pack to slide under it. Doing that not only keeps you from needing longer cables, they can then be VERY short.
I use 16mil cables of 1m each and have no problems welding 0.2 strips.

Heating of the electrodes is a much bigger problem then the inductance.
 
Alan B said:
The inductance stresses and blows out parts.

that is why i got a spare. :wink:
 
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