Gallery, Projects and General > The Design Shop
Microwave owen transformer spot welder?
PekkaNF:
ONE person said that he has 30*10 mm copper buss barrs....length 2400 mm! I'm pretty sure that is pricey. But it's only 90 km (one way). Not too bad.
Now...If I would cut a 40 mm piece of that bar and make a v-groove for electrode holder. Multistrand cable is easy to attach on that coppe piece, no problem there, but would this two 40 long line contacts give enough cross sectin for the current? Probably yes.
Another idea is to make close fitting 20 hole + slit other side onto piece of this buss bar for the electrode holder and cut a little (17*10*20 mm) lug for the cable connector. This would only work as an connector and there would be a separate mechanical split holder for the arm.
Tonight I'm going to order some electrical parts for the controller.
Pekka
sparky961:
I'm having a bit of trouble picturing your current troubles, but I've thrown in some possibly useful idea starters below.
Have you checked your local building store for a solid copper grounding rod? No idea of the alloy or quality but you'd hope it would conduct well considering the application. Maybe you guys use something different there?
Near the grounding rods you should also find heavy grounding cable. Here it's used for grounding 100A and 200A electrical services. It's not the most flexible stuff to work with but if you're considering bus bars already then flexibility doesn't seem a big concern. You can put them in parallel if you need something with even less resistance.
Do you or any of your friends have a furnace that's hot enough to melt copper? The melting point is almost double that of aluminum, but not outside the realm of home foundry setup. Scrounge whatever small pieces of copper you can (plumbing, electrical, whatever) and cast your own large block whatever size you need.
PekkaNF:
--- Quote from: sparky961 on December 26, 2015, 09:32:12 AM ---I'm having a bit of trouble picturing your current troubles, but I've thrown in some possibly useful idea starters below.
--- End quote ---
I am electrical engineer and I have some experience on various systems. Therefore I'm little apprehensive when I push componenets beyond their intended use. The way low voltage circuit works on resistance spot welding machine is simple on most of the aspects, but there was very little at the university that prepared me to work few volts and thousands of amps...
Right now I'm consentrating on a bit that connects secondary coil conductor on the stationary and moving electrode holder.
The conductor has very fine multistrand braid, about 35mm2, should be fine for short pulse of 1100A.
Electrode holder is 20 mm pure copper bar used on electrical cabinet construction.
This piece has two functions:
1) To connect tranny secondary to electrode holder with minimal resistance, this is not one time operation, but must allow mechanical adjustment.
2) Mechanical: Attach mechanically bar to arm.
This is a small part, maximum linear dimenssion 40 mm, 20 mm hole trough it.
--- Quote from: sparky961 on December 26, 2015, 09:32:12 AM ---Have you checked your local building store for a solid copper grounding rod? No idea of the alloy or quality but you'd hope it would conduct well considering the application. Maybe you guys use something different there?
--- End quote ---
Here copper grounding rodds are steel core, copper cladding.
--- Quote from: sparky961 on December 26, 2015, 09:32:12 AM ---Near the grounding rods you should also find heavy grounding cable. Here it's used for grounding 100A and 200A electrical services. It's not the most flexible stuff to work with but if you're considering bus bars already then flexibility doesn't seem a big concern. You can put them in parallel if you need something with even less resistance.
--- End quote ---
Yesh. We have that type cable too, often consumer grade is 16mm2, not sure of it's composition.
--- Quote from: sparky961 on December 26, 2015, 09:32:12 AM ---Do you or any of your friends have a furnace that's hot enough to melt copper? The melting point is almost double that of aluminum, but not outside the realm of home foundry setup. Scrounge whatever small pieces of copper you can (plumbing, electrical, whatever) and cast your own large block whatever size you need.
--- End quote ---
I'm trying to avoid printtin or castig at this point. Too much to swalow at this point - would set me back months instead of weeks :lol
Pekka
philf:
Pekka,
I can't picture exactly what you're trying to do but why can't you connect the cable directly to one end of your 20mm copper electrode holder?
:beer:
Phil.
sparky961:
--- Quote from: PekkaNF on December 26, 2015, 11:49:13 AM ---I'm little apprehensive when I push components beyond their intended use.
--- End quote ---
Isn't that what this forum is all about? :dremel:
If you're the only one that will be using it and you've designed in enough safety that you're comfortable with it then I say it's well-built for the application. Maybe there's an understood but undocumented limit on the duty cycle, or certain parts of the system that aren't quite to electrical code, but you are aware of them so it isn't a problem (as long as you keep it secure from other people's use). We have all done some risky things with the potential for burning down a house or two, but most people with enough of a brain to succeed with these projects has enough sense to have things in place to prevent catastrophic failure.
If you're building this for someone else, it's a different story entirely.
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