Jeffrey Henderson | DIY Miniature Wire Spot Welder | Precision Wire Frame Modelling System | Part 2

Hi Everyone,

Welcome back to my YouTube channel. It’s been 4 weeks exactly since I uploaded part 1 of my DIY miniature wire spot welder/precision wire frame modelling system. Part 1 was focused on the combining transformers, controls, and the system’s circuitry.

Please see video part 1 of this DIY miniature wire spot welder/precision wire frame modelling system -

https://www.youtube.com/watch?v=RF3RUY02hHs&t=504s

Along with this project, I am now working on several additional projects, which will be uploaded shortly on my channel.

In this video (part 2), I focus on a smart mechanism that will form the special clamp that will allow me to edge inside the 30mm rings to weld them to the outer bars/frames.

Also, please see video part 1 of the model (the reason) that I’m building this wire welder -

https://www.youtube.com/watch?v=Dzq1Riqr_tY&t=259s

This proposed specially devised handheld mechanism will be directly connected to both transformer’s secondary windings seen in part 1, where a controlled high current pulse will pass through the work piece to create a minute weld pool. It is important to note that a structural weld is not important here, but a weld that is hidden and is barely penetrating the surface is more desirable as the work piece /model will be for visual viewing. Moreover, the rings once connected at the 4 points, even with the slightest of weld penetration will not move easily inside the contained 4 surrounded bars. Therefore, the current pulse time will be adjusted accordingly for this reason.

In this video, I have created a mechanism that keeps the systems electrodes isolated, which keeps the transformer’s secondary winding open until the weld process begins. This smart device also allows the copper bar/electrode to move in and out freely in a secure capsule along one axis. Moreover, the bar is not prone to drift up or down, or side to side with a very low tolerance for error.

The neighbouring high temperature fibreglass insulators inside the main body acts as a barrier but also a bush, where the copper bar glides in and out over 60mm stroke. However, this will be altered in video part 3 to limit movement.

In more detail, the positive polarity and the negative polarity of the transformer’s supply outputs will be attached at two terminals, where both conducting copper electrodes are isolated from each other using this lightweight, rigid insulation board manufactured from inorganic amorphous glass fibre (RCF) that performs exceptionally well at elevated temperatures. In addition, this thermoset glass fibre polyester composite will provide a low thermal conductivity, high compressive strength, and good durability. Thermalate H330 is commonly used in high temperatures ranging up to 300°C. This insulating barrier is held in the custom stainless-steel guide, where the opposite (positive polarity) copper electrode slides in and out during the weld clamping process.

A developed metallic guide containing the positive electrode will be the main body (negative body) of the handheld device (Note; these electrodes must never be shorted during activation of the foot pedal). Therefore, the negative electrode will attach directly at this point (at the stainless-steel body), where the positive electrode will slide freely in and out from the stainless-steel (RCF enclosed) capsule body. Once a weld position is selected, a finger lever (trigger pressure point) will allow the user to pull the positive spring-loaded terminal out creating a larger gap inside the electrodes. Moreover, before any welding process begins, the user should set the workpiece items in place using the preloaded tension spring that creates the desired clamp force. Also, the device will be created in a way that this spring can be interchanged to suit the bar diameters being used for the model/wire frame of their choice. The electrodes can also be altered, shaped, or interchanged to suit the task at hand. This will all follow in the next video of this project.

The idea is to keep the current path as short as possible at the point where the high current cables connect, but also the path from the transformers to the handheld clamp must be carefully considered. The electrodes pressure will be created using a spring to generate enough pinch force for the selected weld procedure.

In the future video (part 3), I hope to finally demonstrate how to clamp various wire pieces together before welding begins (activated by the foot pedal).

I hope you enjoyed this video, please hit the thumbs up if you did. It’s a project I’ve been meaning to cover this past 3 months for my girlfriend’s model. If you want to see this project evolve, please subscribe, and hit the post notifications bell to see the latest from my channel.

Peace out and much love!
Jeffrey 😊

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