Forge projects.

[ganjalover]

this is hand made axe?

 

I try don`t spent too many time near pc I think it is does not helpfull. Also I try don`t sit in mostly case because it is also does not helpfully. but some time anyway interesting read some peoples from other parts of the world. who and how living, who and how thinkig etc.

 

I not so interesting mariguana now but my opinion is not most impostant in this case. Just for myself I try look some other interesting things. but some smoking is anyway here.

[torken]

If it's a handmade ax

Si es una hacha hecha a mano 

 

[ganjalover]

 

 

Today i burned my coils on hard test with sticking of welding electrode. Also i think i burned coils on transformer same way. Welding machine still working but on last tests without induction coil  i saw overload indicator. I think now somewhere is small distance between primary and secondary coils in trasformer. I used only 70 amper of power and more less on this tests. now I know all this tests was bit stupid because it is no need in working, just burned coils from this. and maybe I need new transfomer in welding machine. outside it is still looks fine but inside I saw reducing distance between coils in transformer. now I don`t want replace it one more time, but maybe no other choise in this case, because I can`t test of fix it in other way.

 

 

Spoiler

 

 

 

 

Previous problem with electricity in house was not so serious I just forgot about old protector from short circuit on the network. for last test I made socket bypassing old procetcor. but anyway all wires was very warm after these tests. and other new protector on 16A also turned off on this tests. on this welding voltage in the network dropped from 204v to 185 volts.

[ganjalover]

 

 

I have now five posibility for extraction transfomer from board. Coils looks fine but on some place on secondary coils I found a problems. I will remade it. but primary coil I think I will keep on same place.

 

Also some old woman reading book with smartphone.

 

Spoiler

 

 

[ganjalover]

 

 

I buyed some high temperature tape for transformer. and did some test with old paper tape and this new anyway show more good results. maybe I will remade primary coil with this new tape also. paper tape show not bad resuls but it is not isolation on high power anymore. 

[ganjalover]

 

 

I made primary coil with new tape and here is a big difference. Maybe i will remade it one more time for avoid cutting. here more Cu anyway better I think. trasformer can work even without ring inside but with very low power.

[ganjalover]

 

 

I remade it one more time but difference is anyway big. Crazy stuff.

[ganjalover]

 

 

I don`t know from were so big difference and what way really is better. but now will be like this. maybe I strech this wires.

[ganjalover]

 

 

This time i made like this. Maybe will be bit more cool air inside. And power must be almost same.

 

And decided remade it one more time.

 

 

 

 

 

 

this is the same copper that was wound before. And from factory here was aluminium. this is create very big difference.

[ganjalover]

 

 

Now here all done and i think working. Tests on welding i will do later.

 

 

[ganjalover]

I made some test with new tranformer

 

THis is clear

 

This is with resistance

 

I try check voltage droping regular way and no big difference 62 and 43 volts also as before. but resistance is low for good test.

 

this is with coil

 

[ganjalover]

Also I can write how many money I spended on all this. Of cource I spend more this time because not all time here all was correct. Also I buy some osciloscope. But I will write price only for correct updates to this weldiing machine and without induction coil because it is can be different. i will write in uah. 1 euro it is 26,23 uah now.

 

Weilding machine 1200 uah.

Capacitors 470mkf 450V 2 pc – 210 uah( but i buyed in bit wrong place and it was 260uah as I remember)

Termistors 120d-15 2pc – 12 uah. but can be placed only 1 pc maybe.

Diodes 80ebu 2 pc –150 uah. and some small parts to this on 10 uah(resistor 22om 5w and capacitor 221).

CApacitors 4,7mkf 400V 4 pc – 60 uah.

 

and for transformer 

 

Termal tape – 85 uah

Copper 4mm2 2 metr 30 uah

Copper 10mm2 2 metr 50 uah.

 

but better buy some thing better if have posibility on it. if more copper in wire it is can help avoid heating in trasformer, and wires with silver outside is best in this case. but as for me all this not so impostant just like a best idea for it. even gold will heating more in this case than copper with silver on it. but gold can give a lot power to transformer with same capacity. Any peace of copper possible silvering with electrolysis.

 

 

I think same way for silvering is also possible. For power of transformer most important weight of wire, and for avoid heating most important electrical resistance of metal. in this case aluminium wire even with silver outside wire don`t give a lot of power, but transformer with silvering will be protected from heating very well. also protection from additional heating can increase power bit on hard working. this silvering almost need for hard woking on welding machine. But this time I finish this project without it.

 

Also here actual using wire on many small wires like 0,1mm. just in this case same quantity of copper take a more space, but on 50 khz this tipe of wire is better. as my opinion different typers of wire can give some difference in arc flaming most concentrated arc in one dot on single wire I think it is best for cutting metals and for accurate works as for me. Also for this need good quality of winding on the transformer.

 

Also I replace here resistor of power regulation it is 10 uah and some small parts on 5 uah. Because it is not working from factory.

 

In good day all this updating here cost about 1820 uah, But I spend more  because I did all it first time and only by myself almost. Also I have some induction coils now to this welding machine. and some other part for replacing like additional transistors. Also I buyed some AC voltmeter on 50 uah. AS now for working it is not so important but sometime can be helpfully. Also I can see how many volt dropping in neiborhoods houses from my working. For example from 204 to 185V it is visible on regular lamps. But not very critical. Anyway now all this bit powerfull and take not small power from power network even without regulation maximum power limit in welding machine. From factory all this worked very different.I dont expact results like but good if it is posiible. not every welding machine can work same way like this after updating.

 

 

For induction coils best material is powder iron, transformer steel and if need good flaming on small current best use MgZn ferrites like PC40, P3, H10KT and good amount of turns on it. Also this ferrites can be used for mayking tranformer. same like transformer steel but in this case can be more weight but power will be good also. Ferrites more good for more clear flaming without splatter, and transformer iron is good for starting flame but it mostly case here is more big weight also.

[ganjalover]

 

 

With big capacitor from + to - and resistance on exit show like this but regular voltmeter show 46  volts anyway in this case. also I can get small flame with induction coil and capasitor this way. and this small flame maybe even more strong I think with capasitor. maybe in some day in future I will test capasior this way on welding.

 

With new transformer vpp on oscilloscope look more correct. Maybe bit better now placed both secondary coils and size more similar.

 

 

Also I think on coil here not pure copper here some like brass. 

 

[ganjalover]

 

 

Some new coil for regular working.

[ganjalover]

some measuring with oscilloscope 

 

THis is new coil with resistance

 

 

SAme with capacitor from + to -, in this case if capacitor before coil regular voltmeter show +4 volt, for example from 40V can up to 44V, If capacitor after coil volts is same in this case and no additional power to small flame in this case.

 

 

new soil without resistance on exit

 

 

Capacitor near new coil

 

 

Coils like this without and with resistance

 

 

Maybe it is not most powerfull induction coil wich I ever had. But something new and interesting is anyway here, on this new coil regular small flame is not greatest, but I can make with new coils very small flame on very long time. Before something like this was not possible I think.

 

 

 

Ferrites on new coils is h10k, and some unknown material on 6000 mil. But I think it is high quality ferrites.

[ganjalover]

today I made some final tests in this project and can say problem with overload indicator without coils is not fixed now.

Maybe some problem with curent sensor or it is just don`t work normaly with this power of transformer I don`t know, but with both my coil it is work fine. And I will keep it like now without any changes before it is working, because with coils anyway working better. Maybe possible try some thing like adding additional resistance before current sensor but I will live it on future. As my last opinion problem can be with arc force tehnology in welding machine, it is increasing power on very small time before welding and maybe curent sensor is show overload with electrode sticking in this case. And coils make this contact is more soft, if all like this I don`t see any sens look something more to this. Coils anyway like some protection to this sensor from overload on start of welding. can be like now still all working normally and no need any fixing only some updates to curent sensor circuit for working with new power or turn off arc force, but now coils on exit like some update in this case for fixing this problem. Of cource I can`t be absolutely sure about it just I think this way now. Here inside control chip ka3525 and on 8 leg of it some protection circuit with this parameters Shutdown Threshold Voltage VTH(SD) 0.7 1.3 1.7 V Shutdown Input Current IN(SD) VSD = 2.5V 0.3 1 mA, I think problem go somewere from this circuit on 8 leg of chip. I anyway will using it like now and only if something broke more I will try fix it. As now all look like this protection circuit must working like now without any changes just need restart every time after shutdown from overload. And overload only after using without additional coils now.

 

THis is from past time I just clean bit before putting new

 

 

THis new here

 

 

AS for me all is still powerfull now, I try create some test hole on 110-120A and no problem with it, I try welding on minimum power and no problem with it, with new coils flaming is very well on minimal power. I think now 3mm electrode is minimal for working. wires is warm this time also. Here is on welding machine 1,5mm2 wire from factory, before I buy 15 metres additional wire also 1,5mm2 because welding machine was not so powerfull as now, and now all this wires is warming. After warming wires resistance on it is more and protector from short circuit on power network is shotting down. 

 

Spoiler

 

 

 

And with this results I will finish. I think here will be no news about it in future.

[ganjalover]

 

Today I decide make some additional test on minimal power just on cold metal and results was different than before, but for me it is no so bad because I think I can use more thin electrodes in this case in future.

Spoiler

 

Also I decide make some big solid peace of iron because some time I need some like this for covering grapes for example also it is good test for me and this welding machine on real working, this all not so important for special metal preparations before welding but is same time better do it maximum solid because also maybe I will hit something by hammer on it is future. Not all I made very good because I was try different way and some time I was lost correct patch after this but almost final result is fine. here important choose correct current for good result which will float the edges of the metal bit, in this case it was 80-90A, also if hole is big maybe better don`t try fill it at once. I don`t have good result with it. in other all fine I think. V type movies by electrod working good in this case as for me, not very slow and not very fast. 

 

 

Today in power network was around 204 volts.

 

Spoiler

 

 

[torken]

Good work friend 😉 👍