6pence Resistance Spot Welder

Place for dealers to post items for sale.
User avatar
pguk   100 W

100 W
Posts: 107
Joined: Mar 16 2012 4:30pm
Location: North England, birthplace of the Industrial Revolution

Re: 6pence Resistance Spot Welder

Post by pguk » Apr 19 2018 2:02pm

Neat video Andi.
I charged my pack lately after it had sat over winter. I bulk charge and don’t use a bms. Cells were all at 4.13V except one, which was 4.14V. I discharged this one bank through a bulb for a few seconds - all good.

Shipping to USA for the kit will be around 8 GBP.

I finally invested in a JBC soldering station. This makes the power board build so much easier although there is still a good few hours work involved in assembly. I have one for built and ready for a good home. I may build more if there is interest. I ask 80 GBP for the assembled power board.
6pence spot welder https://endless-sphere.com/forums/viewt ... 31&t=81274
"It is all nice and proper, but only an idiot would think that the father is sixpence to the good on the transaction." C.S. Lewis' Mere christianity

User avatar
Storapa   100 W

100 W
Posts: 121
Joined: Sep 21 2014 3:33am
Location: UK, Warwickshire

Re: 6pence Resistance Spot Welder

Post by Storapa » May 05 2018 5:11am

I've just welded yet another pack together. Friends at work now use my spotweld for building packs for various drones and bike lights.

It's welded hundreds of cells together so far and hasn't missed a beat. I've just remachined the welding tips for the first time, but that is all that has been required.

A great little spot welder.
Daily machine. - Giant Toughroad, Mac 8T, Thun torque sensor, Phase Runner, CA V3
Scratch built machine - Crystalyte HS 3540, 12 fet IRFB4110 Infineon controller, CA V3, 74v - 20Ah Lipo battery pack. https://endless-sphere.com/forums/viewt ... =3&t=75457

User avatar
pguk   100 W

100 W
Posts: 107
Joined: Mar 16 2012 4:30pm
Location: North England, birthplace of the Industrial Revolution

Re: 6pence Resistance Spot Welder

Post by pguk » Jun 08 2018 9:10am

Storapa

Great feedback, so glad it’s working for you :D
6pence spot welder https://endless-sphere.com/forums/viewt ... 31&t=81274
"It is all nice and proper, but only an idiot would think that the father is sixpence to the good on the transaction." C.S. Lewis' Mere christianity

henrynz   1 µW

1 µW
Posts: 2
Joined: Feb 01 2019 10:50pm

Re: 6pence Resistance Spot Welder

Post by henrynz » Feb 16 2019 11:03pm

Hi all, first time poster + first time youtube video!

Thanks for all the info everyone has provided on this topic and particularly pguk for the unit itself. I recently bought a unit with the power board pre-made.

I made a video so that someone considering the unit for thicker nickel (0.3mm) might get more insight of what kind of setup could be involved. My unit uses two car batteries of about 580CCA each. I appear to be getting 0.3mm pure nickel to weld well. Any suggestions appreciated and hopefully I can do an update later of a completed setup. Overall very happy with the unit but I've only been testing it briefly. :bolt:


henrynz   1 µW

1 µW
Posts: 2
Joined: Feb 01 2019 10:50pm

Re: 6pence Resistance Spot Welder

Post by henrynz » Feb 23 2019 7:58pm

Sorted out my wiring a bit, made some better copper tips from scrap copper but they seem to be leaving a layer of copper on the nickel and I think it would be best if they were physically attached so that the distance stayed consistent:

Image

I've been having reasonable success with settings similar to below, next step is probably to make a welding pen that holds the tips together and to add a trickle charger to batteries so that welds are consistent. Welds are really hard to rip apart but the six spots are still quite variable across the tab so I still need to limit more variables I suppose.

Image

User avatar
pguk   100 W

100 W
Posts: 107
Joined: Mar 16 2012 4:30pm
Location: North England, birthplace of the Industrial Revolution

Re: 6pence Resistance Spot Welder

Post by pguk » May 06 2019 12:23am

Sweet :flame: :D
6pence spot welder https://endless-sphere.com/forums/viewt ... 31&t=81274
"It is all nice and proper, but only an idiot would think that the father is sixpence to the good on the transaction." C.S. Lewis' Mere christianity

User avatar
ridethelightning   1 MW

1 MW
Posts: 1869
Joined: Jul 21 2013 9:48pm

Re: 6pence Resistance Spot Welder

Post by ridethelightning » May 07 2019 1:43am

gotta be happy with that :D

jerome_speedy   10 mW

10 mW
Posts: 33
Joined: May 25 2015 3:39pm
Location: Lyon, France

Re: 6pence Resistance Spot Welder

Post by jerome_speedy » Sep 05 2019 10:30am

Hi guys and pguk in particular,

I come back on this very topic and forums because my 6pence spot welder has failed for no obvious reason.
My last welding job on cells dates a little back (several months). Now, when I connect the supply battery (the one for the board), the LCD doesn't turn on... AT ALL. I checked the voltage goes to the board, yes I have 12,6V.
I thought it could be just the LCD not working anymore with the spot welding still working... but no go.

I opened the box to check if there was any loose wire or something suspect. Well, I can't see anything wrong (no burn or damaged part). The copper wires for welding are tightly screwed to the solar battery (which definitely works).

My spot welder is sitting on a dry "desk" (a plastic box turned over rather) in my garden shelter. So the problem could be due to corrosion (the board looks great, I can post pictures when I have more time). Also, the spot welder is permanently connected to the big solar battery, while not being powered itself. Maybe this could be a problem in the long run ?

I can't think of any other reason for failure (there was not heavy item drop on the spot welder, or anything damaging).
So your input is appreciated :(

User avatar
spinningmagnets   100 GW

100 GW
Posts: 11528
Joined: Dec 21 2007 10:27pm
Location: Ft Riley, NE Kansas

Re: 6pence Resistance Spot Welder

Post by spinningmagnets » Sep 05 2019 11:49am

What city are you in?

jerome_speedy   10 mW

10 mW
Posts: 33
Joined: May 25 2015 3:39pm
Location: Lyon, France

Re: 6pence Resistance Spot Welder

Post by jerome_speedy » Sep 05 2019 12:01pm

Lyon (FR), it's written near my avatar

Now that I come to think of it, maybe the damage occurred when I dropped a RCA male connector (with 54,6 V, low impedence) in the area where is sitting the spot welder. I know that this accident forced me to change a fuse in a boost converter used to generate the 54,6 V but it might have damaged the spot welder board as well (it's just I didn't see it). I have contacted pguk to see if something can be done for repair....

User avatar
spinningmagnets   100 GW

100 GW
Posts: 11528
Joined: Dec 21 2007 10:27pm
Location: Ft Riley, NE Kansas

Re: 6pence Resistance Spot Welder

Post by spinningmagnets » Sep 05 2019 5:19pm

The view of the forum is compressed when looking at it on my smart-phone, so the city was not shown.

I "think" I have a six pence kit in my pile of un-finished projects...but France is a little far to ship (if that is even a real country...)

https://cyclurba.fr/

jerome_speedy   10 mW

10 mW
Posts: 33
Joined: May 25 2015 3:39pm
Location: Lyon, France

Re: 6pence Resistance Spot Welder

Post by jerome_speedy » Sep 06 2019 11:34am

If his Majesty is willing to send said item to the not-real country of my miserable self, I'll be forever grateful.

Failing that, if anyone reading this thread can point me to a module that can drive the mosfet module that I presume is still working, I'd take that too.

User avatar
pguk   100 W

100 W
Posts: 107
Joined: Mar 16 2012 4:30pm
Location: North England, birthplace of the Industrial Revolution

Re: 6pence Resistance Spot Welder

Post by pguk » Sep 07 2019 2:40pm

Hey bro,
Apologies, I only saw your pm today. ( how do you get the sphere to send an email when a post has been made to this thread??)

You have 12.6 volts at the control board? Okay so the control board is seeing power. Can you tell if there is power at the mcu chip? Like, is it getting about 5 volts there? Also is there power at the mosfet driver chip (your input voltage less a protection diode drop of .7v)?
Is the LCD led backlight lit? If not, perhaps the 7805 regulator has popped.

I made the MCU and the FET driver chip socketed so they can be swapped out if they fail. I could send you any or all of: MCU chip, a mosfet driver chip, an LCD, and even a 7805 regulator. All of these I still have stock of. Should get you up and running as long as the power board is healthy. (Can you test there are no shorts on power board? The only thing we can replace there is the Schottky diode..)

I’ll pm you :)
6pence spot welder https://endless-sphere.com/forums/viewt ... 31&t=81274
"It is all nice and proper, but only an idiot would think that the father is sixpence to the good on the transaction." C.S. Lewis' Mere christianity

jerome_speedy   10 mW

10 mW
Posts: 33
Joined: May 25 2015 3:39pm
Location: Lyon, France

Re: 6pence Resistance Spot Welder

Post by jerome_speedy » Oct 26 2019 12:16am

A quick message to say that my spot welder is working again thanks to Paul who sent me a new board + LCD.
The power board was left untouched by the high voltage surge, thankfully.
I can now spot weld like before 8)
Thanks so much Paul for all your advices and your quick reaction

User avatar
pguk   100 W

100 W
Posts: 107
Joined: Mar 16 2012 4:30pm
Location: North England, birthplace of the Industrial Revolution

Re: 6pence Resistance Spot Welder

Post by pguk » Oct 27 2019 3:41am

Awesome, thanks for the update 👌
6pence spot welder https://endless-sphere.com/forums/viewt ... 31&t=81274
"It is all nice and proper, but only an idiot would think that the father is sixpence to the good on the transaction." C.S. Lewis' Mere christianity

tomaj   10 W

10 W
Posts: 74
Joined: Nov 12 2010 5:01pm
Location: Slovenia

Re: 6pence Resistance Spot Welder

Post by tomaj » Feb 14 2020 11:48am

Hi all!

I have some difficulties with welding 0,25 mm nickel.

Two issues, probably connected:
- welds are to weak, you cen easily peel off the nickel strip. Like the welding current is to low.
- Electrodes are sticking to the nickel.

Power source is 4S 123 20Ah battery. Welding cables are 35mm2.

I have tried several settings, but with no luck.

Any advice?

Post Reply