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  1. S

    kWeld - "Next level" DIY battery spot welder

    Great! Did you set the total cable length accordingly(1.4m)? Your system total resistance seems ~7.7miliohm. If you add to this the resistance of welded parts which is approximately ~0.5miliohm results in a total resistance of ~8.2miliohm. If you multiply 0.0082r with 1600a you will get the...
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    kWeld - "Next level" DIY battery spot welder

    First thing you need to do is to set the total cable length to 1.5m and this will limit your kweld maximum current to 1500a Wrong, you have to add also the resistance of the kweld internal switch, the resistance of the wires after kweld and electrodes and also the resistance of the welded...
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    kWeld - "Next level" DIY battery spot welder

    Nice welding arm, is it cnc guided?
  4. S

    kWeld - "Next level" DIY battery spot welder

    Today I replaced the fuse in my welder. With the new one I get again 1.43mR when calibrating. When the original one was still good I got 1.45mR. Seems the original 300a fuse is very close to this 350a littlefuse.
  5. S

    kWeld - "Next level" DIY battery spot welder

    In the future I have to change the fuse anyway so looking around I found this one LITTELFUSE 157.5701.6301 No gold plating so nothing else to be changed. No copper to weld for now so no stressing on the fuse. It will be replaced when a new order for a power pack is received or if the actual...
  6. S

    kWeld - "Next level" DIY battery spot welder

    Thanks for confirming this. The measurements it takes on cells and supercaps seem to be ok. I will search a bit to see if I can manage to change something. I do use a washer under the fuse. The idea was that adding the washer between the fuse and cable shoe adds extra resistance which I wanted...
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    kWeld - "Next level" DIY battery spot welder

    I was thinking at a 400A one but not sure yet mostly because in the same time you stress the fuse you stress the mosfets too. @tatus1969 is it recommended to go with fuses above 300A and with the welder above 100J? this meter takes the measurements at 1khz ac and not dc so the difference could...
  8. S

    kWeld - "Next level" DIY battery spot welder

    Hello Bob, Thanks for taking your time in doing the measurement. I use the fuse that came with the welder. When I weld at 100-110j the pulse duration is 100-110ms. Looking closer to the graph in the link you attached I see that a 300A fuse withstands ~1700a for 100ms. Speaking of meter...
  9. S

    kWeld - "Next level" DIY battery spot welder

    Hello guys, After the high energy(>100j) testing that I have done lately I managed to degrade a bit the fuse. I say degrade because the metal inside lost it’s golden look and became a bit blacker. The fuse still measured 0.25mR(don’t know how much it measured initially). Also I noticed that...
  10. S

    kWeld - "Next level" DIY battery spot welder

    If you go to 5mm the distance between the welding points increases too, when welding you will need to rotate a bit the pen if the electrodes don’t fit the strip.
  11. S

    kWeld - "Next level" DIY battery spot welder

    I seen the same ones you linked but it seems I remembered the price for others from sunstone which are completely in tungsten. https://sunstonewelders.com/products/micro-welder-electrodes/micro-resistance-welder-electrodes/tungsten-micro-welding-electrodes Do you have the ones you linked? How...
  12. S

    kWeld - "Next level" DIY battery spot welder

    I think I seen something like this, a set was ~35$ but unfortunately not good for my pen. They were 5mm diameter and I need 3mm. For the needs I have now 0.1mm copper does well so I think I will remain here as a maximum thickness for the copper. thanks I will need one for each cap and I’m not...
  13. S

    kWeld - "Next level" DIY battery spot welder

    You always use this force or only when you weld using the sandwich technique? I think it more like “due to the high energy the wires heat up quite fast” and the wires heat up the electrodes too. I found interesting the following classes: 13, 14 and 21 though the most interesting seems class 13...
  14. S

    kWeld - "Next level" DIY battery spot welder

    Thanks @qwertyES ! I used a kitchen scale. The sum of the forces for both electrodes was always 4kg(i press with the pen on the scale until I hear the pen switch going on). I started with 2kg for each electrode and then modified it to be 3kg with 1kg(the maximum difference). I...
  15. S

    kWeld - "Next level" DIY battery spot welder

    Hmm a few posts earlier I shared an image from this article. Seems that I forgot more than I know but here comes into play the great community around here! It’s great having you around!
  16. S

    kWeld - "Next level" DIY battery spot welder

    Sorry for missing it. A big thanks for sharing it again with me!
  17. S

    kWeld - "Next level" DIY battery spot welder

    It’s not that I need(for now) 0.2mm Cu neither it’s current capability but I wanted to know how far I can go reliably. I had the 0.2mm Cu strip at hand and because of that I used it. Lately I had a few requests for high power packs so from there the curiosity. The packs that I weld daily are...
  18. S

    kWeld - "Next level" DIY battery spot welder

    After searching a bit around I think I got the answer, I needed 100-110J for this job. So I charged the 2 caps at 5.4V(above this voltage the welder goes into overcurrent protection when I try to weld, when I try to calibrate it goes into overcurrent protection above 4.8V ) to get 1700a. At...
  19. S

    kWeld - "Next level" DIY battery spot welder

    Here is an example, to make it more obvious I increased the energy to 60J for the first two welds from top to bottom and 70J for the bottom one. On the left is the negative electrode and on the right the positive one.
  20. S

    kWeld - "Next level" DIY battery spot welder

    There is something that bothered me since I had the original electrodes and I still encounter with the actual pen. When I weld there is one spot that is stronger and the other one is a bit weaker. The stronger ones is where I have the negative electrode and the weaker is on the positive...
  21. S

    kWeld - "Next level" DIY battery spot welder

    I mentioned in an earlier post that I charge my 4s1p (3000f 3V caps) power source to 5.5V. This got me 1750A in the calibration process and 1450A when welding. I’ve been thinking lately to remove 2 caps and see how it goes. I wanted to do this because it’s easier to move around 700g than 1400g...
  22. S

    kWeld - "Next level" DIY battery spot welder

    So in this case if I choose r7=10k I will need r3=19.09k
  23. S

    kWeld - "Next level" DIY battery spot welder

    Thanks
  24. S

    kWeld - "Next level" DIY battery spot welder

    You are right but this implies having the resistor values in house else I have to solder back the trimmer to have the welder working until I get the resistors and disolder it again when getting the resistors. I don’t want to heat up the pcb 2 times but if I have to..
  25. S

    kWeld - "Next level" DIY battery spot welder

    Hello Frank, I use my kSupply to generate 5.5V and would like to replace the single turn trimmer with 2 fixed resistors. How can I calculate their value? Thanks.
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