How to Make Battery Spot Welder DIY || Use Capacitor & Laptop Charger
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- Опубликовано: 10 сен 2024
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Mr Electron - Use Capacitor Bank operated spot welding machine at home DIY . Make 18650 li-ion battery tab spot welder using electrolytic capacitor & charging it with a laptop charger .
By : Omar Suhaib
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sir shall I use 16v 1 amp power supply instead of laptop charger ??? thax
Raajasekar TNT for this capacitor???? 33,000uf
creativ electron7m yes 33000 MFD 63 v DC
Raajasekar TNT you can try it but u don't think it will work... it needs atleast 18.5V
creativ electron7m sir every think as per your set up but not welding only on the negative side where we touch the battery deep spot created but on the nickel strip nothing happened why will you please explain what mistake
Similar Home Made battery tab welder ---> ruclips.net/video/1SMUFSiaV-8/видео.html
Thanks for the support :)
Safety first my man
Excellent use of using what you have to get the job done!
Very easy to make,useful and safety circuit in 20VDC laptop charger output voltage.The light bulb in series is current limiter load avoiding short circuit of the charger and after the welding lights showing that capacitor has fully discharged and the cycle is ended.Congratulations!!
By far the easies to make.. I like it very much.. Might make one in the future to put together some li-ion batteries for my rc airplane... Thank u for sharing!
Thats a good idea!!! Keep it up!!
Using the magnet for holding the battery was smart...
Getting the extra benefit of magnetically holding your tabs was genius!
Thanks :)
creative electron7m Hi friend, thinking about not to use soldering , is possible to use magnet to keep wires in contact with the battery instead of use soldering? Thanks
Magnetic bonding is not that stron.You will have to do soldering or spot welding eventually. :)
--> ruclips.net/video/uR7kPllswys/видео.html
artier
God principle demonstration. Thanks. I really like you use of the magnet.
....success and quality of the weld
Excellent video.
Exactly what i wanted.Thanks.
Thanks :) :)
one person commenting on one video with different accounts 😂😂😂
@6:28- Ufff as he tugs and pulls the welded copper electrode off the strip.☺
It's not the capacitance that is the critical factor here, it's the total energy available to be released. You say that you have tried smaller caps with no success but while that may be true at the voltage you are using, all that is required in order to use a smaller capacitor is a higher voltage or parallel some. Also, as the energy increases with the square of voltage (max energy stored is CV^2/2) a higher voltage means a relatively smaller cap. This principle is used in all SMPS that utilise the high energy stored from rectified mains voltage in a relatively much smaller capacitor (a few to a few hundred uF) compared to a normal mains transformer with VERY large capacitors as the storage caps after transformer output rectification.
33000 uF charged to 10v = 3.3*10^-2*10^2/2 = 1.65 Joules.
33,000 uF charged to 20v = 3.33*10^-2*20^2/2 = 6.6 Joules
10,000 uF charged to 20v = 10^--2*10^2/2 = 0.5 Joules
10,000 uF charged to 50v = 10^-2*50^2/2 = 12.5 Joules!!
So for 6.6 Joules in 10,000 uF just use ... V^2 = 2*E*/C so root (6.6*2/10^4*10^-6) = root 1320 = 36.33 volts to get 6.6 Joules
Or get hold of several 10,000 uF caps and parallel them. Benefit from much lower stress on individual caps, effectively lower overall ESR (paralleled ESRs) and faster energy output (IF you even need it) :D
Pay your money (nothing if scrap!) and take your choice
I use a 63v WDC 10,000 uF cap that I've had for AT LEAST 38 years, probably longer!! Works fine between 38 and 50 volts, tab thickness depending. I have numerous other large (>10,000 uF) at different voltages I could use too. Use rounded tip or truncated cone copper or brass electrodes of about 2.5 to 3.5mm diameter for best results. Use ANY power supply you can get as you only NEED a transformer and suitable bridge rectifier. Whilst a laptop supply should suffice - it's overkill for the job. Play safe with the output and put a series resistor or VDR after the rectifier to limit the inrush current to the capacitor.
Check out a VERY professional set up (not mine) - ruclips.net/video/Ceos88VO6p4/видео.html - there are a whole series of videos to see for the final circuit - and he's still developing it!
Hi Bob. I am really confused as I have found such conflicting information about capacitor spot welding. I read an article online in which it was stated that 200 joules is around the discharge energy needed to spot weld battery tabs. I am aware that a crutial factor is the THICKNESS of the nickel strip being welded. I read that the capacitor you use discharges much less than 200 joules. I have 2 questions: 1) do you use pure nickel strips or nickel plated steel strips; 2) what thickness of strip do you use? I am using 0.15mm pure nickel strip because the load needs to draw 30-40 amps max. Cheers Bob
good
So it doesn't matter that you are touching bare wire at the point of spot weld?
Okay Sir, your advice is much appreciated, thanks. I still need to claritfy some points. Can you please send me a link to the circuit diagram for the setup you have in this video, so I know for sure I am getting my connections right.
Also, can you tell me what formula you use to determine the current which will flow through the bulb? I still need to learn more about the process. Thanks so much
I don't have that but i have something similar : www.instructables.com/id/Best-Lithium-Ion-Battery-Tab-Spot-Welder-NO-Super-/
Good and thank you sir
Mohammad Farhan You're most welcome 👍
which capacitor is recommended for a car battery? I've already seen that people have the welding diodes clamped directly to the battery, but that seems a little thin (not enough output)to me.
Nice holding trick with the magnet!
Nigel Pearson thanx :)
bro, shall i use 33000 mfd/ 25v dc???
Why doesn't the capacitor discharge onto your hands, when you hold both electrodes?
Okay, I still need to clarify. If the bulb is only in series with the power supply and the capacitor, surely the wire coming from the +ve capacitor terminal connects to the bulb, then the power supply, and then to the -ve terminal of the capacitor? Otherwise, where can the wire which comes from the power supply be connected if not to ONE of the electrodes?
Hi is it works since I tried in many capacitors like super capacitor 3V 500F but its not works properly
great demo! I assume you can also use a dc charger instead of ac? I have a cap from a microwave, will that work? I think it is rated at 300v. I rather not mess with those, Anyone know why only the cap in the vid worked for him?
Hey there, tks for sharing. I just wonder is this safe for the battery?
I think its better to use lead acid bettry for this job...in series with solenoid relay....nd use one piece of wood to hold both copper piece.
Dear Mr. Electron, would you please give more detailed explaination on the fuction of the lamp connection? And How do we know the capacitor not to be charged over its capacity or charged fully?
your materials are a little basic, but they work well! using your welding device, that wont damage the 18650 ends? also, how many spot welds are enough to have the nickel strip stay on securely, mechanically & electrically? thank you
sir every think I used as per you instructions 20v charger 33000 MFD DC 63v capacitor and 18swg earth copper but not welding properly what might be the reason ??
use thin nickle strips
Is charger has to be swtich on at all time while welding also
Sketchy bare wires and charged up caps
Many thanks for this constructive Video ! Yesterday i bought a Microwave for 10€ to get the high voltage transformer, but i think your method is much better. In Cina i get a 22000 µF 63V Capacitor for 2.89€. Can i use 2 of these parallel with a 12V bulb or is one Capacitor enough ?
I think you should use at-least 2 in parallel for stronger welds.
Many thanks for the very quick anser !!!
MAC KNACK any time 😀
Yeah at first I thought that I'd have to get a Microwave transformer too , to be able to tab weld . But this is a great idea .
Mr Electron please tell me, what is the best shape for the tip of the electrodes to be for the best, most even weld? Thanks
Thanks
:)
Hello Mr Electron: I have 2 x 22000uF/63v capacitors, can i use them in parallel (44000uF) and will it perform as per your settings?
ish khan yes it should work 🙂
Thank you & cheers.........happy new year 2018 Mr Elactron
Sir, from your video I can see that there are TWO wires coming out from the +ve terminal of the capacitor. It appears that the bulb is connected to the -ve copper electrode. As such, it would appear that the bulb is in series with the power supply and the -ve copper electrode. If I am wrong, please explain what really is the case. Thank you
Hi friend. I have managed to solve the bulb problem which is great. But, can you describe the shape of the tips of your copper conductors? I believe the exact shape of the very end of the electrode significantly affects the success quality of the weld. Best wishes
one should be pointed and other one flat
Nice idea, love the ingenuity, but if you see a black and white o/p wire on a charger then it is probable US connections which is Black is + ve and white - ve, always you should check the polarity with a meter, revers charging of electrolytic caps and cause them to explode, seeing this video I suspect he was getting away with it as he was limiting the voltage to 20v. Also make a foot switch to make the weld and bring the electrodes close together separated by an insulator, much easier to use.
The Joker No.. black is -ve and white is positive which is the standard rule.Yes always check the polarity. before installation
The Joker No.. black is -ve and white is positive which is the standard rule.Yes always check the polarity. before installation
No in the U.S.A. electrical wiring for AC in residential and commercial applications Black is +, positive, and White is - , negative. The white wires are always connected to the neutral buss along with any bare copper wire or green in some circumstances which is used for ground, and the black wire is connected to the circuit breaker which is attached to the positive buss. For DC black is negative and red is positive for 99% of connections but if you have any questions always check the polarity with your meter.
I agree with the joker, a lot of appliance wiring is made for U.S . So white is neutral, please test with meter.
Nice video
Vivekkumar Vivekkumar Thanks 🙂
Hi. My query is quite simple but crutial to being able to repeat what you have in this video: there seems to be hardly any RESISTANCE in the discharge circuit. This being the case, how on earth can it be possible to discharge the inevitably high current through a bulb which is rated only to handle about 5 amps at the very most? Using I= V/R, let's assume the resistance is about 1Ω. So the peak discharge current surely would be 20 AMPS!! How can you pass 20 Amps through a 12 Volt bulb rated at around 70 Watts without disctroying the element and therefore the bulb? Please help me see the theoretical mistake I am making, because I have already destroyed 3 such bulbs using the circuit arrangement outlined in your video. THANK YOU !
current passing through the bulb is only 1Amp .Bulb is not connected in series with the capacitor and the electrodes but between the charger and the capacitor. Also watch this : ruclips.net/video/1SMUFSiaV-8/видео.html
I have 55 F 30v lying around. Can I use that for spot welder ? Would it be possible if I charge it using only 12V power supply ?
How many times have you shorted that mess of wires out. Not dangerous but i bet it maked you jump.
While spot welding is it possible to leave it connected for longer periods of time? It doesn't over charge because the capacitor is a Max 60v DC and the laptop charger is at 20v DC? I am not an electrician, just trying to make a cheap spot welder for my bike batteries so please excuse the layman questions...
correct
Mr Electron cool, actually I found another capacitor which is a 25vdc at 330,000uf so I guess I can use this single one to spot weld instead of using multiple 100kuf in parallel...let me know plz
Abid Khan Yes it will work.
Mr Electron thanks!!
Mr Electron, at higher voltages as in our video, during a discharge, please explain how you reduce the current passing through the bulb to a level it can handle but also allowing the spot weld to happen? Is it a case of connecting a resistor to the wire coming out from the +ve capacitor terminal? I am doing something very wrong because I keep blowing my 12 volt bulb during discharge!!
electron become proton
Bro please help me
I buyed 50mfd (50,000uf) 440v, still I am not able to stick even shaving blades
Voltage is way to high.... Use less voltage capacitor 50,000uf
@@MrElectron why?
Even with high voltage I am not able to attach two blades
What's wrong I am not understanding
Hi Sir. I have been considering other important aspects which dictate the degree of heat build up required at the weld site. One is the melting point of a given metal being used. I can confirm that the nickel strip I am using is virtually PURE NICKEL. It is not NICKEL ALLOY like the one you use. I was advised to only use pure nickel because it helps protect the batteries from overheating when high currents are to be drawn from the pack. I am aware that pure nickel has a significantly higher melting point than copper-nickel alloy. Do you know what alloy of nickel your strip is? It would be very helpful for me to know if it is a STEEL NICKEL ALLOY or a COPPER NICKEL or other alloy. Please let me know. Thank you!
I believe it could be more effective to use the ground electrode to apply pressure on the tab to the battery so that the initial spark discharge is fully dissipated into the weld rather than on the tab alone. Thank you for the video! Have you tried this technique with solar cell tabbing?
Kirk Doray correct.
No, i havn't tried it with the solar cell tab welding.
your explanation couldn't be better.. Thanks :)
Hi professor, in other video you use capacitore 100 farad. 3,7 volt, but in this video you said down 33000 micfarad can't work?
I have a couple quick questions if you have the time. I was looking around for a cap this large so I could replicate this and fix some batt packs I have. I got a car audio cap nearby and pretty cheap, but I have some concerns. First off it's rated at 20 volts max, and I believe your supposed to have 20% room for error. I think that only drops me down to 19.8V, however the cap is .5F!!! (500 Thousand micro-Farad). I charged it up using a 12 V battery and it took at least 30+ seconds to level out, but when I disconnected the battery, the voltage started dropping fast. It has a digital Volt Meter built onto the top side of the cap, so once power is disconnected, the voltage starts dropping quick, so I'd have to keep it hooked to a power source. I thought for a bit and figured I could use a momentary push switch on one of the leads from the cap, then I could keep it on a charger/battery, and still have control.
SO; Think this Cap would do good spot welds while running on just 12-15 volts at .5F, keeping it hooked to the power source with a switch from the cap to be able to control the pulse, OR, should I start over and get a better suited Cap??? Any Help would be appreciated!!
da1cru1 The voltage shouldn't go down fast for a capacitor of such high capacitance as in 0.5F .It means that the capacitor has completed its life.. Still it can work as a good spot welder at 16V charge considering the discharge time.
Thanks for the reply; The cap is brand new, as in I took it out of the plastic packaging. Actually I exchanged it today for a new one as I fried the circuit board that holds the voltmeter. I think I may have had a bad one?? This one charges like a reg cap does, it just takes a second instead of nearly instant. That might depend on the PSU,I was using a "back-up" type 12V battery, if I had a higher current "push" or ability, I IDK if it would charge quicker?
I have not tried to make any sparks with this one yet, I'm trying to break it in, for lack of better words. I was getting good sparks but not even strong enough to hold 2 pieces of the battery strip together? But I'll see if it works.
It's a wierd "Style of car audio caps, "Scosche", you can find them on ebay, I got mine at wall-mart.
higher charging current will decrease cap charging time
What's the light bulb for
battery short ckt protection
I see electrode welding to the strip more than quite well.
Do you have any attempts to reduce welding current by incomplete charging of capacitor?
Can you say about how to calculate welding current from capacitor and time of welding by capacitor disharge?
Igor Morozov Gr8 question.I will revert soon :)
A = U^2 * C/2
А = U * I * t
I = (U * C/2) / t
Any proposal, Am I wrong?
Can I use 150,000uF 35V to make this sir?
Yes
nice
Thanks :)
Great job, best professor I see . can work without magnet?. thanks.
Faysal ziadi yeah! Thanks ☺️
creative electron7m can work without magnet?
Faysal ziadi yes sure it can
creative electron7m .What will happen to the capacitor if you charge it more than its capacite? Yu charge it directly from power hall. Thanks.
it will burst open
Hi Sir. My question is, if the capacitor(s) you are using have tab terminals instead of screw terminals, and you do not have crimp spade connectors is it okay to attach crocodile clips permantely to the ends of the wires and secure the wires to the capacitor tabs with crocodile clips? It is convenient because it is not a permanent connection like soldering the wires to the terminals, but I wondered if it affects the effectiveness of the discharge of the capacitor and hence its ability to spot weld effectively? Thank you
Nope
what is the purpose of the light bulb, other than to let you know the caps are charged? Couldn't you skip the bulb, and just assume the capacitor is charged after a few seconds?
It limits the inrush current when charging the capacitor. (Capacitors don't like too high inrush currents). And it protects the power source from a short circuit when welding. (You could use a resistor instead.)
Wow , Thanks for this tutorial . I like how You used the lightbulb as a resistor to limit surger current for the power supply . Also , nice capacitor , I'm jealous . Thanks Take Care :)
Kyle R 😊😊😊
If I was to use resistors in its place, what would you recommend?
I plug the charger into the wall. The light bulb briefly flashes. I attempt a spot weld. After that nothing happens. The light does not flash again and it does not charge capacitor.. I have to unplug and plug adapter back into wall. What am I doing wrong?
I guess my bulb didn't take enough amps because when I added a computer fan it cycled correctly, but now it seems I don't have enough power. Will adding another capacitor in series help. Also I am using only 18 volt adapter cause it's what I had.
I guess you are not welding it properly.Bulb barely flashes means the caps have charged so thats fine but now tiuch the terminal s to the battery and make it spark
Sir I have arranged this with old laptop charger I have two Doubts a). I have 18SWG earth copper piece shall i use it ?? &B) this nickel strip where its available ?? or shall we use copper wire or aluminium strip ??
Raajasekar TNT A)You can try the earth copper B)nickel strip is available on ebay.
thank you sir
Raajasekar TNT how to a
creative electron7m,
please show me, the +/- charger connect to which pin of capacitor? ( I can't to see the +/- on capacitor)
+ of the battery will be connected to the + of capacitor and same for the -ve
Could you tell me what kind of light bulb do you use??
Use a headlamp bulb from a car.
Thank you very much!!
Were did you got that capacitor
Ah, I see now. So one electrode has been hammered flat. Because it is flat, it must create increased resistance to current flow and hence an high resistance connection inbetween this electrode and the battery, whereas the electrode touching the nickel strip makes a relatively low resistance contact. What is the advantage of this over a situation where both electrodes have pointed ends? Does it help to limit the surge of the current and so make it less likely that a hole will be blown through the nickel during the weld? I am curious to understand every little detail of your device because there is no question that spot welding is very much an exact science, the right balance struck between heat transfer and control of the welding process. So far I cannot reproduce welds of the quality of yours, and need to keep refining my procedure. Thanks
Its just that for pointed electrode, heat will be focused to a specific point and vise versa for the other electrode.
I see. Well, my electrodes are exactly 3mm diameter and I have tried putting a point on one. The problem I encounter is that with a point, even at 20 volts on the capacitor it blows a small hole in the nickel strip. I am using 0.15mm strips, so not too thin. When I made the electrode flat, it tends to avoid blowing through the nickel which is good, but it tends to melt the nickel only partially and so only a tiny spot on the battery melts, not enough for a strong weld. Sometimes it fails to weld. If I truncate the tip even very slightly, more often than not it blows through the nickel. I can't seem to strike the right balance. Just to be sure, is your electrode truncated with a small diameter spot on the end or does the point have a straight edge, rather like the edge on a wood chisel?
MR ELECTRON IF YOU ARE THERE, CAN YOU ANSWER MY QUESTION THEN I WILL LEAVE YOU ALONE, THANKS
??
Awesome tutorial. Where can I get the capacitor? I am from Assam.
From scrap market usually..
Sir Will you please inform that serial Bulb V and wattage Thanks
Raajasekar TNT 12V 72W
Dear Sir where do you reside I live in chennai
Raajasekar TNT I live in UP , Lucknow
Great Invention Thank you sir Shall v use less then 33000Mfd sir ??in market only 10000Mfd available
Raajasekar TNT connect 4 ; 10,000MFD in parallel and you will get 40,000MFD
the most Indian video on youtube
very funny way
can i use ac capacitor with thsame capacitance sir?
arsenio guinat sure
I just a newbie.Can I ask you is there any danger in handling a capacitor.Because the energy stored in it and a voltage almost 72v that you can be electricuted.
No the voltage is only 20V since the charger is only 20V so no electric shock.I touch it with bare hands all the time..Since you are still learning stuff ,i will recommend that u take all the safety measures until u are fully confident :)
Hmm.. say that the capacitor is rated at 300v if I charge it using 20v.The dischage voltage is just only 20v or near.
correct.
Thanks for the response brother.
sure thing :)
where to buy capacitor
No entiendo, tienes conectado un transformador de PC de 60W al condensador?
No te da corriente al tocar los cables?...gracias.
Add a micro controller to this
Sir The copper is ready made electrode or shall we use the copper from any wire ?? or earth copper
Raajasekar TNT the copper is from a shaded ring induction motor
creativ electron7m sir I need only few packs if I send the cells will you do it for me ?? I shall pay for it ( if its hurts you sorry) sir
No worries.. But i will think about it and revert :)
Sir, please explain something for me: there would appear to be very little resistance in the circuit containing the bulb. If 20V is stored in the capacitor, then by I= V/R, assuming the resistance is say just 2Ω, the initial discharge current it 10Amps. How does the bulb, rated 12Volts and about 70Watts, handle that initial discharge current given that, by I= Power/Voltage, the bulb is designed to handle around 6 amps max???? How does the bulb element not just blow out???? Surely you need a resistor to be placed before the bulb??? PLEASE ANSWER MY QUESTION, AS I NEED TO UNDERSTAND THIS ISSUE BEFORE PROCEEDING.
I actually build this project it work!!!
felix44860 😀. Thanks for the feedback felix44860
Man, this thing throws a spark from hell!!!! It is awesome!
felix44860 yes it does.Awesome indeed! 😎
Maha.indrajal
The video technology seems to be 21st. century, so why did you choose 19th century wiring style? For aesthetic reasons?
no specific reason.
It's only a demonstration video... and it works doesn't it ?
Looks pretty dangerous
用1、88v~3v充大電容點焊不會有太大火花
english??
RESCON - Made in India
من خیلی خلاقیت ونوآوری رادوست دارم
再加一個按鈕
my ears are dying
Very dangerous.. can just use soldering..
Sabahan Ranau Its really difficult to solder nickel strips to the batteries thats y we do spot welding.
there is no security guard
This is so amazingly CRAPPY!
This is pathetic beyond every known level! :-)
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