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Manufacturing welding machine "Kid"

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Manufacturing welding machine "Kid"

The welding machine operates on 220 V mains and has high electrical characteristics. Thanks to the use of a new form of magnetic circuit, the weight of the device is only 9 kg with dimensions of 125 X 150 mm. This is achieved by using tape transformer iron, rolled into a torus-shaped roll, instead of the traditional W-shaped plate pack. The electrical characteristics of the transformer to the torus of the magnetic core is about 5 times higher than that of the W-shaped, and the electric losses are minimal.
To get rid of the search for a deficient transformer iron, you can buy in the store ready LATR for 9 A or use a torus magnetic core from a burnt laboratory transformer. To do this, remove the fence, fittings and remove the burnt winding. The released magnetic circuit must be isolated from future layers of the winding by an electrical card or two layers of varnished cloth. The welding transformer has two independent windings. In the primary, a 1.2 mm long PEV-2 0 wire with a length of 170 m is used. For convenience, you can use a shuttle (wooden rail 50 X 50 mm with slots at the ends), on which the entire wire is pre-wound. An insulation layer is placed between the windings.
The secondary winding - copper wire in cotton or vitreous insulation - has 45 turns over the primary. Inside the wire have a turn to turn, and from the outside with a small gap - for uniform location and better cooling. It is more convenient to perform the work together: one carefully, without touching the adjacent turns, in order not to damage the insulation, pulls and puts the wire, and the assistant holds the free end, protecting it from twisting. A welding transformer manufactured in this way will produce a current of 80-185 A.

If you purchased LATR for 9 A and upon inspection it turned out that its winding was safe, then the matter is greatly simplified. Using the finished winding as the primary, it is possible to assemble a welding transformer for 1 hour, giving a current of 70-150 A. To do this, it is necessary to remove the fence, the current collector slider and mounting fittings. Then, identify and mark the leads for 220 V, and the remaining ends, securely insulated, temporarily press against the magnetic circuit in order not to damage them when working with the secondary winding. Installation of the latter is carried out in the same way as in the previous version, using copper wire of the same section and length.
Assembled transformer is placed on an insulated area in the old casing, pre-drilled holes in it for ventilation. The wires of the primary winding are connected to the 220 V network using a ShRPS or GRP cable; It is necessary to provide in the circuit an automatic disconnecting device AP-25. The terminals of the secondary winding are connected to the flexible insulated wires of the PRG, the electrode holder is attached to one of them, and the welded part is attached to the other. The same wire for the safety of the welder is grounded.
Current adjustment is provided by the connection of a ballast-holder electrode with a 3-mm nichrome or state-standard wire and a length of 5 m, rolled up into a trap line, which is attached to the asbestos cement sheet, in series with the target. All wire and ballast connections are made using M10 bolts. By the method of selection, moving the point of connection of the wire in a “grid”, set the required current. It is possible to adjust the current using electrodes of different diameters. Electrodes of type E-5RA UONII-13/55 - 2,0-UD1 1-3 mm are used for welding.

All the necessary materials for the welding transformer can be purchased in the trade network. A person familiar with electrical engineering, to make such a device is not difficult. When working in order to avoid burns, it is necessary to use a fiber protective shield equipped with an E-1, E-2 light filter. A headdress, overalls and mittens are also required.
The welding machine should be protected from moisture and prevent its overheating.

Approximate mode of operation with a 3 mm electrode: for a transformer with a current of 80-185 A - 10 electrodes, and with a current of 70-150 A - 3 electrodes; after which the device must be disconnected from the network for at least 5 minutes.