BOSS LEVEL CUSTOM SPOT WELDER

Check my electrodes videos hummie

[youtube]hkQBYMse_DI[/youtube]
You can find 1.5 copper rods at aliexpress
 
rojitor said:
I did this weekend a shockproof pack for a Trampa mountainboard. My customer is more of an animal than a human so it really needs to be rock solid to last in his hands.
I used both welding and the neodinium magnets technique. The welds are really really unlikely to fail due to vibrations and continuous hard landings.

The neodinium magnets technique has been widely discussed at this very forum. Once the magnets are epoxied/glued or stuck somehow they do not let the copper sheet move. I used 0.1 copper sheet and my boss welder.
I used a smart bms to charge to 4.10v the cells, skip voltmeter and lock the battery. Controlled by Xiaoxiang app android.
It has high density foam on and under the pack so it can absorb vibrations. Of course insulated with kapton, barley paper and eva foam. The spacers grant both natural cooling and increase greatly the structure strength. Has some glass fibre tape too.
It's been put inside a carbon fibre box and has a fuse protection.
There's no way to destroy this pack ;)

I taped part of the proccess. I will make a video if i find some time.
Click to expand...

Great design! I'd be really interested to see a video of that build. By the way, could you explain why you did spot-welding + using magnets? Would the magnets not have been sufficient to provide a reliable and secure connection? Also, could you share how you did attach the main battery leads to the copper sheets? Would soldering a thick cable on the copper sheet not compromise its flexibility? It seems you didn't extend the copper sheet passed the cell holder to make the connection on the side...

Thanks!
 
Thanks

I dont see any round 1.5mm copper rod on amazon. How u think magnet wire with its thin insulation will work? 15awg is close to 1.5mm. I have 16 awg at 1.3mm and will try that unless I read a good reason not to. It’s a long thread and welding is new to me but isn’t there some other material that could replace the copper that won’t deteriorate?
 
Times are tough at the mo , deepest sympathies Rojitor.
I am off to funeral on Thursday my wife's granny, my wife has been her full time carer for 30 months.
 
Hope the best for you


16awg works ok for the electrodes. Cheaper maybe. A bit narrower. Cleaned the enamel off w a fancy tool too.
I have many misfires due to the electrodes not making good contact. Worth getting thicker electrodes for their rigidity probably. Often I have to cut back or grind back the shrink
 
I have two of these units.
One of them started intermittently not recognizing that contact between the electrodes was being made and now it will recognize it at all. There are no error messages on the screen.
Where should I start looking / checking for problems?
 
my Boss spot welder flickers "fet error" and beeps, and i turn it on and off a couple times and the flickering stops and it works again. i go back to welding and again make another big blowout with no cell behind the copper shooting blindly, and it goes back to flickering "fet error" and its not seeming to come back now. its stuck on "fet error". i prayed to the gods many times and this time seems its not coming back.


i dont think these welders are made anymore. how to get it fixed? whats another reliable welder that will do the .1mm copper sheet ive been using?
 
Mine says fet error and won’t work. Anyone fix these?


I’m in need of something that will weld .1mm copper so I can finish this battery. Any recommendations for something I can get fast to Cali?

It said fet error after I welded without the cell being pressed firmly and causing a big blowout in the .1mm copper, then it came back, then I did it again, then it came back, then I did it again and something shot off from the welder and it smells like gunpowder. Think it’s dead for sure now.
 
Hummina Shadeeba said:
my Boss spot welder flickers "fet error" and beeps, and i turn it on and off a couple times and the flickering stops and it works again. i go back to welding and again make another big blowout with no cell behind the copper shooting blindly, and it goes back to flickering "fet error" and its not seeming to come back now. its stuck on "fet error". i prayed to the gods many times and this time seems its not coming back.


i dont think these welders are made anymore. how to get it fixed? whats another reliable welder that will do the .1mm copper sheet ive been using?
Click to expand...

I don't know the Boss spot welder but I'm guessing that the FET error is quite likely to be exactly that- the Field Effect Transistor(s) may well be damaged - when i was learning electronics my boss told me that transistors are a component you put in a circuit to protect the fuse :) Even modern high current MOSFETs are easily damaged by brief spikes of too much current or voltage
Anyway, opening the unit up and replacing the FETs may not be too difficult a job. It may be worth looking. The FETs will have a heat sink and be connected between the negative welding lead and the power supply ground. There may be several in parralel. Read the code off the part, buy some from RS, Farnell, Mouser or Ebay and replace all of them in the set. Likely to cost a couple of dollars/quid each and could save you buying a new welder. You should replace all of them as a set.
There are ways to test them but if you can use a soldering iron then replacement may be an easier job.
The other thing that might go is the driver chip - I blew one on my welder (it burnt a hole in it which I spotted). Each of the FETs will have a thinner wire to a chip - perhaps a 6 or 8 pin chip which is likely to be connected to the control circuit (microcontroller etc) again, read the code, replace. Cost me £4 to fix mine. Post a pic of it's guts and someone will point out the relevant bits I expect.
 
Hummina Shadeeba said:
Mine says fet error and won’t work. Anyone fix these?


I’m in need of something that will weld .1mm copper so I can finish this battery. Any recommendations for something I can get fast to Cali?

It said fet error after I welded without the cell being pressed firmly and causing a big blowout in the .1mm copper, then it came back, then I did it again, then it came back, then I did it again and something shot off from the welder and it smells like gunpowder. Think it’s dead for sure now.
Click to expand...

The IRF1404 FETs are blown. I've also blown them twice already trying tungsten copper alloy electrodes. You can replace them with these from Amazon.

https://www.amazon.com/gp/product/B07P2K6979/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

I would replace all of them and not just the blown ones. But if you want to know which ones are blown you will see a circle with lighter shade of metal on the back of the FETs.
 
Hummina Shadeeba said:
I see them for sale on eBay. Guess they’re still for sale. Need something stat if u know a welder that can do .1mm copper.
Click to expand...

It will do nickel plated 0.15mm copper. Like these:

https://www.ebay.com/itm/Pure-Nickel-Plated-Copper-Strip-Tab-0-15mm-x-8mm-18650-US-Sales/133104900617?var=432415150001&_trkparms=ispr%3D1&hash=item1efdab9a09:g:azYAAOSwplBdH6OQ&amdata=enc%3AAQAFAAACgBaobrjLl8XobRIiIML1V4Imu%252Fn%252BzU5L90Z278x5ickkBUIiHwYv5YgVss0WaiENz5lxCb1iE0UoCE7aZU6meiKFYF%252BTpiVWlkhkCXU9ayNMZOcugycklcx1NufQl0RvxBQ%252ByWv5G13tFzD51UXWH6lePNFnV6tnqg9i%252F%252FbSvN%252BsKeISSKEw0lfQfMOFPpxlX2%252Bwd0WUUA4VR3Fe%252Bn5xbbsClVwXRvB9EQ51GmHJQUcCwOseCq9cRV0T3NbHz7tH73AgSQyodl%252BDvU%252BMSjBdWntcoOMKAcq%252Fi1hZQW62ZF1ayFMe%252BRBqHERScpq1PeYN25QNrALm26Sj7%252FY%252F0leQ%252F8O1uHpjyekhjMfzHjCcLiqyqslma6a7s7kWxipHrwKbga3TEoezHgQqBpMbUitnKmOOHK%252Fes4eM4kWMxm9ccPUbFNaz8PmnL21Lb5ISu%252Fx6KFhBvkbXWYB1aiu5bsSf2MnWrVJfUFVhLDeXe%252Ffnc10WPkt%252F2rsaI106u1X%252BnhN4AnTRX0gUoj6Ss99ZddV7wJcpFnr7I2J4%252FKGi3Dz9c8Y3Nm%252BfxzBiFr1Hrx51RYHvKW8PxZOan8F3bVAZF%252FmFUym9c1G37ag8rgmEk0MaoVKxhoYM1oXzkA3JNPpTS%252BLX7D6OeOPu61O5Zqs6bDHvCWa%252FBO5Zfiwji8Bn8IVlK%252FH%252Bv5XT3PgqEWWBmBg7foUE2B%252FIR6dVGyqCyX%252BuAGvNlGrCO9%252By7IRUkBmQPpqSoHvLreaEtTJa3MT9DtEcq3lWhWcrlyY1APUhROLEc68kL4xs%252FhOM%252BoWSxsgK80tlZMY3sYdCxT33P6DusabmmUatY%252BaPv7IHXrD2IJVAhVc6A3g%253D%7Ccksum%3A13310490061711e50dfce7a3402a8f20d243f10bb9a9%7Campid%3APL_CLK%7Cclp%3A2334524

He also sells 0.3mm plated copper. This welder will not weld those. Ask me how I blew the FET's twice already.
 
Ciclon said:
Hummina Shadeeba said:
I see them for sale on eBay. Guess they’re still for sale. Need something stat if u know a welder that can do .1mm copper.
Click to expand...

It will do nickel plated 0.15mm copper. Like these:

https://www.ebay.com/itm/Pure-Nickel-Plated-Copper-Strip-Tab-0-15mm-x-8mm-18650-US-Sales/133104900617?var=432415150001&_trkparms=ispr%3D1&hash=item1efdab9a09:g:azYAAOSwplBdH6OQ&amdata=enc%3AAQAFAAACgBaobrjLl8XobRIiIML1V4Imu%252Fn%252BzU5L90Z278x5ickkBUIiHwYv5YgVss0WaiENz5lxCb1iE0UoCE7aZU6meiKFYF%252BTpiVWlkhkCXU9ayNMZOcugycklcx1NufQl0RvxBQ%252ByWv5G13tFzD51UXWH6lePNFnV6tnqg9i%252F%252FbSvN%252BsKeISSKEw0lfQfMOFPpxlX2%252Bwd0WUUA4VR3Fe%252Bn5xbbsClVwXRvB9EQ51GmHJQUcCwOseCq9cRV0T3NbHz7tH73AgSQyodl%252BDvU%252BMSjBdWntcoOMKAcq%252Fi1hZQW62ZF1ayFMe%252BRBqHERScpq1PeYN25QNrALm26Sj7%252FY%252F0leQ%252F8O1uHpjyekhjMfzHjCcLiqyqslma6a7s7kWxipHrwKbga3TEoezHgQqBpMbUitnKmOOHK%252Fes4eM4kWMxm9ccPUbFNaz8PmnL21Lb5ISu%252Fx6KFhBvkbXWYB1aiu5bsSf2MnWrVJfUFVhLDeXe%252Ffnc10WPkt%252F2rsaI106u1X%252BnhN4AnTRX0gUoj6Ss99ZddV7wJcpFnr7I2J4%252FKGi3Dz9c8Y3Nm%252BfxzBiFr1Hrx51RYHvKW8PxZOan8F3bVAZF%252FmFUym9c1G37ag8rgmEk0MaoVKxhoYM1oXzkA3JNPpTS%252BLX7D6OeOPu61O5Zqs6bDHvCWa%252FBO5Zfiwji8Bn8IVlK%252FH%252Bv5XT3PgqEWWBmBg7foUE2B%252FIR6dVGyqCyX%252BuAGvNlGrCO9%252By7IRUkBmQPpqSoHvLreaEtTJa3MT9DtEcq3lWhWcrlyY1APUhROLEc68kL4xs%252FhOM%252BoWSxsgK80tlZMY3sYdCxT33P6DusabmmUatY%252BaPv7IHXrD2IJVAhVc6A3g%253D%7Ccksum%3A13310490061711e50dfce7a3402a8f20d243f10bb9a9%7Campid%3APL_CLK%7Cclp%3A2334524

He also sells 0.3mm plated copper. This welder will not weld those. Ask me how I blew the FET's twice already.
Click to expand...

Thanks for your help! Can I replace the fets with a solder iron?


That plated copper looks nice but this time I have .1mm copper sheet.
 
Sure you can. But you do need some experience with a solder iron. It's not what I would call easy.
 
Ciclon said:
Sure you can. But you do need some experience with a solder iron. It's not what I would call easy.
Click to expand...

im pretty good at soldering.

just unscrewed the bottom plate which seems closest to the fets and its not coming off easily. i thought was just held with thermal paste to the fets but is it more?
 
Got one of these in April 2020 and just now finally getting around to build a battery with it. I'm using canned food lids to test on since they should be the same thickness as a battery shell. I have tried with and without sanding off the coating. Since I didn't like and had no luck with stock electrode setup I got one of these spring loaded ones https://www.amazon.com/dp/B09BFQ7HC3?psc=1&ref=ppx_yo2ov_dt_b_product_details

I could swear my initial tests went fine and 5ms 1x was sweet spot. A day or two later I remembered to test nickel on nickel but cant get them to weld even at 16ms 2x. Double checked nickel to lid and now that's weak even at 16ms yet 6ms seems to at least get the negative side probe to weld ok wile the positive side is weak. I'm now debating if I should try replacing the fets or the battery. Figured I'd ask here before spending money based on guesses. Oh and the battery I have is a Turnigy Bolt 5400mAh 3S 11.4V 65~130C LiHV that I got about the same time as the welder. I also played around with tip spacing and shape but that doesn't seem to make much difference. I also tried auto instead of using the switch since the springs are pretty stiff and that oddly does seem to weld a tiny bit better so I may look for some softer springs.
 
I have prepared everything ready and have welded about 20% of 0.2-mm Cu pad + slotted 0.15-mm Ni-plated steel (sandwich technique) for my 20S3P Samsung 21700-40T pack. Unfortunately, I accidentally touched one probe of my kWeld after a spot was just welded, pulse was released 1100A @120J already. The other probe was still on that spot and foot switch released. A spark occured without me know that. Now my kWeld cannot do any welding. It keeps cycling 10J, ...,...,... in an endless loop. The control knob does not respond to my click or turn. So, I contact Frank and still waiting for his response. Don't know how long. Or whether it is fixable. Now I'm stuck in the welding process. See pictures.

So, lesson learned, I need a back-up welder.

Can anyone pls let me know whether this BOSS Level spot welder can weld my sandwich 0.2-mm Cu pad + slotted 0.15-mm Ni-plated steel tab ? And whether this welder can use a ac-plug-in power supply of some kind, instead of Li-Po 4S, 5000mAh, 30C RC pack. Because I do not own that Li-Po pack.

Or if there is any other welder that can weld my set-up, I'm all ear. And I need this new welder urgently. Need to finish this pack quickly.

Cannot attach MP4 VDO.


386281.jpg


386282.jpg


386283.jpg
 
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