My son's 24'' MTB conversion

[cybug]

More pics : https://plus.google.com/photos/+GuillaumedeBailliencourt/albums/6028938144325737009

Pics of the DIY Spot welder and battery pack welding : https://www.flickr.com/photos/95721093@N05/sets/72157643383857074/

 

[contador]

Nice job.

 

[kfong]

Nice spot welder, do you have info on the design. I've seen microwave ones created, but have not seen your version with the display.

 

[Tench]

You might want to check he has enough tyre clearance to the battery to accommodate the front suspension travel, it might prevent a face plant! Difficult to tell from a pic, he may have checked and it is safe to use?

 

[cal3thousand]

You might want to check he has enough tyre clearance to the battery to accommodate the front suspension travel, it might prevent a face plant! Difficult to tell from a pic, he may have checked and it is safe to use?

That was the first thought on my mind too...looks dangerously close.

 

[cybug]

You might want to check he has enough tyre clearance to the battery to accommodate the front suspension travel, it might prevent a face plant! Difficult to tell from a pic, he may have checked and it is safe to use?

Yes of course ! Double checked ! It doesn't touch in any case, even with me (90Kg, twice the weight of my son) on it, pushing and braking as tough as I can. The fork got only about 50mm effective travel.

 

[cybug]

Nice spot welder, do you have info on the design. I've seen microwave ones created, but have not seen your version with the display.

It's based on this one : http://www.avdweb.nl/tech-tips/spot-welder.html

I've replaced the Inverse parallel SCRs (I burnt) with a SSR from ebay ( http://www.ebay.fr/itm/24V-380V-40A...ate-Relay-Module-3-32V-DC-To-AC-/310733040176 ).

I've modified the firmware to support push buttons and display :

/* 
Arduino resistance spot welder timer
 
Copyright (C) 2012  Albert van Dalen http://www.avdweb.nl
This program is free software: you can redistribute it and/or modify it under the terms of the GNU General Public License
as published by the Free Software Foundation, either version 3 of the License, or (at your option) any later version.
This program is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the implied warranty
of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License at http://www.gnu.org/licenses .
Version 10-9-2013

Guillaume de Bailliencourt (Cybug) : Add support for menu with push buttons and display.
*/
 
#if ARDUINO >= 100 
  #include "Arduino.h"
#else
  #include "WProgram.h"
#endif
//#include <Streaming.h>
#include "switch.h"

// using LiquidCrystal library
#include <LiquidCrystal.h>
// select the pins used on the LCD panel
LiquidCrystal lcd(8, 9, 4, 5, 6, 7);

// define some values used by the panel and buttons
int lcd_key     = 0;
int adc_key_in  = 0;
#define btnRIGHT  0
#define btnUP     1
#define btnDOWN   2
#define btnLEFT   3
#define btnSELECT 4
#define btnNONE   5
 
const byte spotWelderButtonPin = 52; 
const byte spotWelder = 53;
 
bool continuousWelding = 0; // enable continuous welding
bool startWelding = 0;
unsigned long startWeldTime = 0;
int iterWeld = 0;
int preWeld_ms = 50;
int step_ms = 150;
int weldPause = 500;
int tSelect = 3;
 
Switch spotWelderButton(spotWelderButtonPin);
 
void setup() 
{ Serial.begin(9600);
  pinMode(spotWelder, OUTPUT);
  lcd.begin(16, 2);              // start the library
  updateDisplay(0);
}
 
void loop() 
{
   
 
  spotWelderButton.poll();
  if(continuousWelding) weld(spotWelderButton.on());
  else  
  if(spotWelderButton.pushed()) weldCyclus(step_ms);

 //lcd.setCursor(0,1);            // move to the begining of the second line
 lcd_key = read_LCD_buttons();  // read the buttons

 switch (lcd_key)               // depending on which button was pushed, we perform an action
 {

   case btnRIGHT:
     if (!continuousWelding) {
       tSelect += 1;
       if (tSelect >=4) tSelect = 1;
       updateDisplay(300); 
     //lcd.print("RIGHT ");
     }
     break;
   case btnLEFT:
     if (!continuousWelding) {
       tSelect -= 1;
       if (tSelect <=0) tSelect = 3;
       updateDisplay(300); 
       //lcd.print("LEFT   ");
     }
     break;
   case btnUP:
     if (!continuousWelding) {
         if (tSelect == 1)
          preWeld_ms += 1;
        else if (tSelect == 2)
          weldPause += 50;
        else
          step_ms += 10;
    
     updateDisplay(300); 
     //lcd.print("UP    ");
     }
     break;
   case btnDOWN:
     if (!continuousWelding) {
         if (tSelect == 1)
          preWeld_ms -= 1;
        else if (tSelect == 2)
          weldPause -= 50;
        else
          step_ms -= 10;
          
       updateDisplay(300); 
     //lcd.print("DOWN  ");
     }
     break;
   case btnSELECT:
     {
       continuousWelding = !continuousWelding;
       updateDisplay(300); 
     //lcd.print("SELECT");
     break;
     }
     case btnNONE:
     {
     //lcd.print("NONE  ");
     break;
     }
 }
}

void updateDisplay(int ms_delay)
{
  lcd.setCursor(0,0);
  
  if (continuousWelding)
  {
    lcd.print(" Welding while  ");
    lcd.setCursor(0,1);
    lcd.print(" pressing pedal ");
    delay(ms_delay);
    return;
  }
  
  if (tSelect == 1)
    lcd.print("<Pre>Pause Weld ");
  else if (tSelect == 2)
    lcd.print(" Pre<Pause>Weld ");
  else
    lcd.print(" Pre Pause<Weld>");
    
  lcd.setCursor(1,1);
  lcd.print("     ");
  lcd.setCursor(1,1);
  lcd.print(preWeld_ms);
  
  lcd.setCursor(5,1);
  lcd.print("      ");
  lcd.setCursor(5,1);
  lcd.print(weldPause);
  
  lcd.setCursor(11,1);
  lcd.print("     ");
  lcd.setCursor(11,1);
  lcd.print(step_ms);
  
  delay(ms_delay);
}
 
void weldCyclus(int weldTime_ms)
{ 
  lcd.setCursor(0,0);
  lcd.print(" << WELDING >>  ");
  
  //lcd.setCursor(0,1);
  //lcd.print(">");
  
  pulseSpotWelder(preWeld_ms);
  /*
  lcd.setCursor(0,1);
  lcd.print(" ");
  lcd.setCursor(4,1);
  lcd.print(">");
  */
  delay(weldPause);
  /*
  lcd.setCursor(4,1);
  lcd.print(" ");
  lcd.setCursor(10,1);
  lcd.print(">");
  */
  pulseSpotWelder(weldTime_ms);
  
  //lcd.setCursor(10,1);
  //lcd.print(" ");
  
  updateDisplay(0);
}
 
 void weld(bool b)
{ digitalWrite(spotWelder, b);
  if (b)
  {
      lcd.setCursor(0,0);
      lcd.print(" << WELDING >>  ");
      if (startWelding != b)
      {
        startWeldTime = millis();
        startWelding = b;
        lcd.setCursor(0,1);
        lcd.print("                ");
      }
      
      if ((iterWeld++ % 50) == 0)
      { 
       lcd.setCursor(0,1);
       lcd.print("    ");
       lcd.print(millis() - startWeldTime);
       lcd.print("ms");
      }
  }
  else
  {
    startWelding = 0;
    iterWeld = 0;
    updateDisplay(0);
  }
}

void pulseSpotWelder(int ms)
{ digitalWrite(spotWelder, 1);
  delay(ms); 
  digitalWrite(spotWelder, 0);
  //Serial << ms << endl;  
}

// read the buttons
int read_LCD_buttons()
{
 adc_key_in = analogRead(0);      // read the value from the sensor 
 // my buttons when read are centered at these valies: 0, 144, 329, 504, 741
 // we add approx 50 to those values and check to see if we are close
 if (adc_key_in > 1000) return btnNONE; // We make this the 1st option for speed reasons since it will be the most likely result

 // For V1.0 use the one below:

 if (adc_key_in < 50)   return btnRIGHT;  
 if (adc_key_in < 195)  return btnUP; 
 if (adc_key_in < 380)  return btnDOWN; 
 if (adc_key_in < 555)  return btnLEFT; 
 if (adc_key_in < 790)  return btnSELECT;


 return btnNONE;  // when all others fail, return this...
}

 

[kfong]

Thanks, glad I asked. I will keep an eye out for a microwave now.

 

[cybug]

First off-road test ride OK !

 

[arkmundi]

It's based on this one : http://www.avdweb.nl/tech-tips/spot-welder.html

Thanks for the detailed post on your spot welder

 

[Brake]

It's based on this one : http://www.avdweb.nl/tech-tips/spot-welder.html

Thanks for the detailed post on your spot welder

X2

Nice job!

 

[SloNEZ]

Looks like one happy kid!
Nice job.