How to make a welding machine for welding twists

Do-it-yourself twist welding machine

Welding work is performed during any construction, repair, installation and adjustment of electrical equipment; the most common is welding of strands of copper and aluminum wires.

And if sometimes welding can be done using a soldering iron, when the melting temperatures of metals are not high, then in most cases it is necessary to use a special welding device. Such equipment has a very high cost, which will not pay for itself with one-time use, so the purchase of welding equipment is not very profitable.

However, there is a way out of this situation - to assemble a machine for welding twists with your own hands; in order to cope with this task you do not need much effort and time for preparation.

Purpose

Welding wires of various metals is also being replaced by conventional twisting under pressure, crimping, which is the clamping of metal wires into a cylinder under load, and so on. However, only welding can ensure reliable contact of two metal wires, as well as proper transmission of electric current.

Process technology

Welding of wires is carried out in several stages:

1. Removing the sheath and insulation of the wire to the metal wire;
2. Performing twisting. There are several ways to twist correctly; you can find them on the Internet;
3. After this, using pliers or a file, cut the twist so that the length of both wires is the same, the length of the twist should be approximately 60 mm;
4. Next, a heat-removing clamp is put on the twist and welding is performed using a carbon electrode; a small ball of fused metal is formed at the end of the twist;
5. After hardening, the twist can be insulated using electrical tape or heat shrink tubing;

Thus, everyone can carry out this procedure; there is nothing complicated in it, the main thing is the availability of working welding equipment.

Necessary materials for creation

You can assemble a machine for welding copper or other strands yourself if you have a little experience in electrical equipment. To carry out the procedure, the following parts and tools are required:

• A transformer that is necessary to convert alternating current voltage of the same frequency. To weld copper wires, the transformer must have a power of at least 0.6 kW, and also that the voltage of the secondary winding does not exceed 30 V. The recommended thickness of the primary copper winding of the transformer is 2 * 0.75 mm and 6 mm of additional aluminum power cable;
• “Crocodile” clips, which are designed to fix the electrode; instead of them, you can use any other clamps, the main thing is that the electrodes lie tightly and clearly in the holder;
• Carbon electrode with which the process is carried out;;
• Aluminum cables, preferably;
• Voltage regulator;
• Wires with a large cross-sectional area;
• All kinds of tools (pliers, screwdrivers, pliers, etc.).

Process of creation

It is better to make a welding machine for welding copper strands by experienced people, as incorrectly connecting one or another element can have a bad effect on its operation. The design procedure includes the following stages:

1. It is necessary to find a casing in which the main element of the circuit - the transformer - will be located; it is best to use a plastic box to reduce the weight of the device;
2. The power wire must be connected to a transformer; wires with a large cross-sectional area must be selected to avoid overheating. It is also advisable to install a switch between the transformer and the power wire, which will serve to turn the current supply on and off, and also provide a small resistance;
3. The power wire is connected to the transformer using a terminal;
4. It is necessary to run two wires from the transformer terminal, also of a large cross-sectional area, one will serve as an empty contact for fixing the twist, the second will serve as an electrode holder with which welding is carried out.

As mentioned above, you can use large Crocodile clips as holders; for an empty contact, ordinary pliers will suffice. It is best to choose long wires for the holders so that you can carry out various welding work on the ceiling or walls without moving the device itself. On larger devices, it is possible to install additional resistance, as well as a current regulator.

Requirements for a homemade welding machine

A homemade welder for twisting metal wires must meet the following requirements, which ensure its efficient and high-quality operation:

• Safety for human life. All wires must be insulated, since in such devices the current strength reaches 60 A, and only 1 A is enough for a person to die;
• The transformer must produce a power of at least 600 W;
• The wires of the holders should not be made too long, since as the length of the wire increases, the resistance increases and the current at the end decreases; the optimal length for a 600 W transformer will be 3-4 meters;
• The casing of the structure must be durable and lightweight so that it can be carried;
• Clamps for twists should be convenient and comfortable; it is also advisable to make special holders for them.

Benefits of use

A DIY welding machine for twist welding has a large number of advantages compared to industrial models, for example:

• Cheapness. All parts included in the design can be purchased at an electronics store; their cost is not very high. Therefore, the creation of such a unit will save a fair amount of money;
• Quality. When a person creates his own welding machine, he performs all actions very carefully and correctly;
• Ease of use. The person who personally created and designed such a unit will understand its structure;
• Light weight and dimensions. Industrial models, like machinery, are very large and heavy;
• Compact, with a casing, the device fits perfectly in a closet.

Thus, a homemade twist welding machine will be an excellent solution to the problem of connecting metal wires. With proper installation and operation, a twist welding machine will serve its owner for more than three years. It does not take much time to understand the connection diagram and operating principle; absolutely anyone can carry out such work with the proper level of training. Why overpay if such a device can be easily made by hand.

Source: https://svarkalegko.com/oborudovanie/svarochnyj-apparat-dlya-skrutok.html

Welding copper wires with your own hands. Review of machines for welding copper wires

Is wire welding important?
Twisting is a very common type of connection for copper wires and is quite reliable. Welding greatly improves the quality of twisting, increasing its reliability and durability.

Reviews from professional electricians and tests from electrical laboratories indicate that twist welding is a guaranteed excellent wire contact that is not subject to oxidation and does not require revisions of junction boxes with tightening of contacts.

In modern electrical installations using expensive wiring components, this is very important. After all, electrics is also the science of contacts. First, let’s look at the options for electric devices for welding twists.

Types of welding machines

There are three main groups of welding machines used by electricians (and not only) to connect wires in modern electrical installations: • narrow-profile welding machines for welding strands of copper wires, such as the TS-700 and its analogues of Russian and foreign production; • general inverter welding machines appointments;

• welding machines of our own production from step-down transformers.

Description of these types of welding machines, their features

Welding machines for soldering copper electrical wires.
Factory-made welding machines for electric welding of copper strands are suitable only for electrical installation of wires. They are very easy to work with twists.

The device body is compact, with a carrying strap. On/off key, power wire, ground wire with clamp or retainer and electrode holder wire. They use special carbon electrodes for welding copper wires.

These machines can weld both rigid and stranded copper wires.

These are ordinary inverter welding machines, but they can also weld copper strands. Such devices are also easy to carry. It is better to use some kind of clamp to connect the ground wire of the device with twist. Also, experimentally it is necessary to select the optimal value of the welding current (from 60 to 110 A). Copper-carbon electrodes are used. Welding current is better constant.

Homemade wire welding machines

These are devices made by skilled electricians from various types of step-down transformers. In general terms, these are transformers with a power from 300 W to 800 W, with a voltage on the secondary winding from 9 V to 36 V. The ground wires and the holder are made of several wires, so that there is from 15 kW. mm. The electrodes in this case are often the carbon rods of the batteries.

How are twisted wires welded?

1. It is necessary to remove 50-60 mm of insulation from the wires and twist them.2. Use pliers or clamps to connect the twist to the ground.3. Electrode for 1 sec. scald the end of the twist to a ball at the end.

4. Cool and insulate the twist.

Who can weld copper wire strands?
Theoretically, anyone, as long as there was an understanding of electricity and electrical installation. Still, it is better to have a professional electrician do the welding of twisted copper wires. You need to pay attention not to burn the insulation of the wires, so that the twist is not short, but a drop of welding, if possible, without holes.

The most important and responsible component of the installation and assembly of power supply systems is. High-quality and reliable contacts at the points of connection of electrical network elements, made in accordance with the requirements of the Electrical Installation Rules (PUE), are a guarantee of operability, durability, and most importantly, electrical and fire safety. In this article we will tell you how to weld wires in a junction box with your own hands.

It is important to know

The simplest and fastest way to solve the issue of how to connect wires is considered to be, but at the same time, twisted wires represent a very low degree of contact reliability. Terminal blocks and crimping devices increase the reliability of installation, but are several orders of magnitude inferior to such a connection method as welding. When preparing for electrical installation, weighing all the pros and cons, you should definitely cast aside doubts and give preference to this method.

People who are not knowledgeable about electrical installation issues have the opinion that this connection method is an unacceptably advanced technological process that requires the highest qualifications of the performer and the use of highly complex equipment. In fact, everything is very simple and accessible. Welding wires with your own hands is entirely within the capabilities of a person who has basic skills in handling an electric welding machine at home.

The question is very relevant for our time, since inverter welding machines became available for mass purchase. The inverter welder is very convenient and practical, with a low current load consumption and reasonable cost, for which it has earned popularity among home craftsmen.

As a device, you can use a homemade device made on the basis of a step-down transformer. For a person who has knowledge and skills in the field of electrical engineering, the question is not difficult.

Electrical installation companies specializing in welding use special welding machines in their work.

What do you need to prepare?

In addition to the apparatus for welding work, you should prepare and have available all the necessary equipment, materials and tools. The wires are welded using carbon electrodes. For the manufacture of conductor products, copper and much less often aluminum are used.

For information, according to the latest PUE requirements, the use of aluminum conductors with a cross-section of less than 16 mm 2 is prohibited. Depending on what will have to be welded - aluminum or copper, the composition of the flux is selected, designed to chemically dissolve the oxide film formed during welding.

In the process of preparing the ends of the conductors and as work progresses, you will need a knife, pliers, and electrical insulating materials.

By the way, an alternative option is . Read our article about how to properly solder wires!

Process Features

Before you start welding electrical wires, you should set up the machine. Considering that the conductors being welded can be of different cross-sections, the current at the anode of the welding machine must be selected in such a way as not to cause overheating of the connected conductors or sticking of the electrode at the connection point. The ends of the conductors must be stripped of insulation (bare conductors must be 5 mm long) and connected to each other, as is done when twisting.

Having pre-treated the twisted bare ends with flux, we clamp them with pliers and attach the mass to them, the electrode is brought to the end of the twist, which should be directed downwards, and held in this position for 0.5 to 2 seconds.

Once you are sure that a copper or aluminum ball has formed at the point of contact, stop welding. After the connection has cooled, remove the flux with sandpaper.

Before applying an insulating coating to welded wires, it is recommended to treat this area with a solvent, followed by coating with electrical insulating varnish.

It is strictly forbidden to connect live conductors. Before starting work, using a probe, you need to make sure that it is missing. To protect your eyes, face and hands from burns when working, be sure to use a protective mask and gloves.

The technology for welding copper wires with an inverter is shown in the video:

For aluminum wires, there is an alternative welding option - using a gas torch. In this case, it is necessary to prepare the current-carrying conductors in the same way as for electric welding, with the exception of flux treatment. To work, you will need a steel rod with a cross-section of about 2 mm. The joint must be heated with a gas burner until signs of melting appear at the welding point at the end of the twist.

When melting, liquid aluminum is enveloped in a kind of cocoon consisting of an oxide film that interferes with the joining process. After making sure that the aluminum has melted, to complete it, it is necessary to destroy the resulting layer of oxide film simultaneously with heating using a steel rod, which will ensure a reliable welding process.

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The main element for welding wires is a welding machine. You can buy it ready-made in a store or make it yourself. Let's consider both options.

Inverter

Factory-made electronic welding machine. Its direct purpose is metal welding. It can be used for welding wires without modification. To do this, graphite electrodes must be used as an electrode.

There are a large number of inverters on the market at an affordable price, small in size and weighing about 3 kg, which is very important for electricians, since they often have to weld wires under the ceiling while on a high ladder.

Source: https://linkor-best.ru/welding-copper-wires-with-your-own-hands-survey-of-devices-for-welding-copper-wires/

Twist welding machine: what is it, how to make it yourself

When replacing wiring, a twist welding machine is required. Most often, the devices are used when renovating an apartment. Copper wires unravel and need to be collected in order to fit compactly in the box.

What it is

A transformer is a device designed for soldering wires. If you look at the cut cable, its edges resemble bristles, with tendrils pointing in different directions. For ease of use of the wires, it is required that the edges be gathered and smoothed. For this purpose, a transformer is used that connects the antennae by soldering.

Twist welding machine

Visually, it represents a large block (the transformer itself), from which the wires extend. Clamps are connected to them, as well as an electrode.

Important! Next to the transformer there is a voltage regulator.

Specifications

When considering transformers, the following indicators are taken into account:

• welding current;
• voltage level.

The voltage ranges from 12 to 36 volts, the welding current starts from 70 amperes to 120 amperes. Much depends on the preparations. If we consider elements with two wires, the welding current should be 70 amperes, provided that the cross-section does not exceed 1.5 square meters.

Advice! Selecting a cable with a cross-section of 2.5 square meters for four wires, the welding current should be 120 amperes.

How the device works

To connect copper wires, alternating, direct or rectified current is suitable. Its voltage value plays an important role. An electrode is used to melt the material, which does not violate the integrity of the metal.

Operation of the device

If you want to get an even, beautiful seam, you need to look at DC models. The melting process is carried out due to reliable contact of the electrode with the surface. In order to control the melting process, a current regulator is required.

The electrode should ideally not stick to the metal. The transformer is responsible for arc welding, so maintaining stable combustion is considered important. Since the device is used on copper, it does not have a high melting point. If we consider steel, we cannot do without a powerful transformer.

As a result, there is no need to achieve a large arc; only short-term exposure is required. As is the case with steel, there is no metal spattering. The electrode is made of carbon. Many DIYers use special rods that are taken from batteries.

As an option, brushes from electric motors are suitable.

When connecting the transformer to the network, the electrode should be brought almost closely to the copper; a gap of up to 1 mm is allowed. During the voltage conversion process, an arc appears and a small ball is visible at the end of the electrode. Since we are not talking about a high temperature, the metal will not become porous, that is, the insulation is not damaged.

Advice! When soldering is completed, the wire is cooled and it is advisable to cover its end with electrical tape.

How to make a wire welding unit with your own hands

If you wish, you can make a transformer for welding copper wires with your own hands. The main issue concerns the selection of materials and tools. During the manufacture of the device, it is better to follow the instructions.

Materials and tools

To make a device with your own hands, you will need the following materials from materials:

• transformer;
• alligator clips;
• carbon electrode;
• aluminum cable - 2 pieces;
• rotary voltage regulator;
• power cable with a cross-section of more than 2.5 mm.

Tools include pliers and a set of screwdrivers. It is advisable to have pliers on hand.

Step-by-step instruction

To make a transformer with your own hands, you must follow the instructions.

Case selection

For homemade products, you need a reliable casing that will protect the transformer. It is important to remember safety precautions, as it is easy to get burned. The box can be made of metal or plastic. If a mobile installation is being made, it is better to use plastic. A metal box is considered more stable, but is not intended for transportation.

Case selection

Transformer

Regarding the base, both electronic and power units are available to choose from. The blocks are supplied by various manufacturers and it is important to decide on the circuit of the thyristor welding device. The circuit provides space for output blocks as well as a secondary winding.

A voltage regulator is selected separately, which is responsible for the rectified current. This technology is actively used to charge batteries. Therefore, similar settings are found in starters from various manufacturers. If the choice falls on an electronic unit, it’s worth understanding its operation a little. The signal generator circuit is taken as the basis, so bipolar transistors are used. Reverse conduction is ensured and high voltage is observed.

Transformer circuit

When selecting an electronic unit, the maximum level of energy consumption, as well as voltage, is taken into account. Homemade modifications for 6 and 9 volts are considered common. In the standard circuit of the electronic unit, the transistors are opened and then the capacitors are discharged along the chain. The thyristor in the circuit works as an amplifier.

As an option, three-winding transformers of the TI series are used. Their peculiarity is their low voltage level. If desired, the element can be created independently on ferrites. Such installations have a high energy conversion rate. During assembly, it is important to achieve the required current value, which depends on the needs.

Power cable

When there is a powerful 24 volt transformer, it is recommended to select the appropriate electrical wiring for it. It is recommended to use blanks with a cross-section of 2.5 mm or more. For safety reasons, it is recommended to install a switch that is connected to the wiring. Thus, if something happens, the installation can be quickly turned off by stopping the current supply.

Power cable

Using Terminals

To power a transformer or inverter, terminals are attached to it using the twisting method. Next, you connect to a 220 volt network.

Mounting the holder and contact

Two wires come from the terminals, one of which goes to the holder, the other to the contact. The welder must be able to hold the workpiece, as well as freely fix the electrode, thanks to which welding is carried out. Specialists do not always use clamps, preferring to work freely with pliers. When taking a closer look at the electrode holder, it is recommended to select long blanks, as they are more practical.

Device holder

The risk of electric shock is reduced, plus it is more practical for the welder to work in hard-to-reach places. The long holder makes it easy to work on the ceiling or in narrow passages. Additionally, if there is a long holder coming from the transformer, there is no need to move it frequently.

How to use it correctly

When using the device, welding experience is required. The main goal is to achieve a high-quality connection; the seam should be smooth and neat. Most often you have to work with a cable of small cross-section. Not all devices are suitable for soldering twists. If we consider the modification with alternating current, it is important to feel the power of the transformer.

When connecting the equipment, the first thing to do is check the electrode and power cable. It is important to clean the wire so that there is no buildup on it. The cores must be stripped of insulation with a margin of 6 cm. During the melting process, it is important to ensure that the insulation is not affected. Before melting, the twist is checked.

Checking twist

Inexperienced welders, the conductors fit unevenly, so it is not possible to make an accurate drop. After twisting, trimming is done. All tendrils must be removed to make the cut look neat. Thus, the surface is heated evenly and the drop just falls on the edge. While working with the electrode, it is important to hold the workpiece with pliers.

The above describes in detail how to make a transformer with your own hands. This does not require special tools or materials. The unit is indispensable during home renovation work.

Source: https://rusenergetics.ru/instrumenty/apparat-dlya-svarki-skrutok

How to make a transformer for welding wires with your own hands and use it

There are many ways to connect wires. They differ in the speed of installation, the quality of electrical contacts, and the ability to operate for a long time under current network loads.

Time-tested twisting with welding has increased reliability. All other technologies are inferior to it to varying degrees.

The article gives advice to the home craftsman on making a welding voltage transformer for connecting copper wires when installing household electrical wiring and a description of the technology for welding them with explanatory pictures, diagrams and a video.

In everyday life, you can find wiring laid using old methods from aluminum or modern ones from copper. Both types can be welded, but since aluminum wires are now reaching the end of their service life and must be replaced by copper wires, we will perform all calculations in relation to the latter.

About wire welding

The process includes the preparation of the cores and their further connection.

Preparatory work

These include:

• cutting the ends of cables and wires, removing insulation;
• twisting of exposed veins;
• preparation of welding equipment.

Features of the technology

To connect wires, you can use alternating, direct or rectified current. Its value should melt copper at the site of application of the electrode without disturbing the internal structure of the metal. In this case, the shape of the applied voltage does not have a significant effect, although it is easier to ensure a good quality weld with direct current.

Welding creates the most monolithic and durable metal alloy with reliable contact. For it, it is enough to regulate the currents within 40÷120 A, selecting them according to the cross-section and number of connected wires: the electrode should not stick, and the arc must ensure stable combustion.

Copper has a lower melting point than steel. There is no need to heat it with high currents or create a large arc. The process takes place briefly, without the formation of a large amount of metal splashes. For short-term work as a welder, it is permissible to use safety glasses instead of a mask to simplify some safety measures. But you should still work in special clothes and shoes.

For welding, a carbon electrode with a copper plating layer is used. It is quite acceptable to replace it with a rod from a used battery or a brush from an electric motor.

Such an electrode is brought close to the twist and immediately withdrawn by 0.5÷1 mm. The resulting arc melts the copper, forming a characteristic ball at the end. The current circuit is immediately broken: the short duration of the process preserves the integrity of the insulation on the wires and eliminates the formation of a porous metal structure in the created seam.

After the metal has cooled, the twist and weld are wrapped with electrical tape (preferably fabric) or covered with heat-shrink tube.

I recommend that you sign the cables entering the junction box immediately. This connection of cores by twisting and welding works reliably for decades. If necessary, checking the electrical circuit of the inscription will greatly facilitate the work of descendants.

About the designs of welding transformers

For welding with twisted electrical wiring, you can use various industrial equipment or make it yourself.

Inverter devices

These modern industrial devices allow you to perform high-quality work, creating good seams even for novice welders.

It’s not at all difficult to buy an inverter for welding in a store. They can also do other chores around the house. But we do not pursue this goal, but are interested in equipment that can be made with our own hands.

Homemade designs

Among the many developments, we will consider two: the simplest and the most powerful, which are not so difficult to implement.

The simplest welding machine

It can be made to replace electrical wiring in a private house or apartment: you just need to select or make a transformer with a power of about 600 watts with a voltage of 220/12÷36 volts.

Strand welding may require a current of about 100 amperes. Considering that the operating mode lasts no more than two seconds, and the arc for each circuit is created with a time delay, the thickness of the wire for the secondary winding and the electrode connection circuit can be selected for smaller loads. Overheating of their insulation will have to be prevented by blowing or interruptions in work.

Where to get a voltage transformer

From ready-made samples, we can recommend a model of the TBS type (armored machine-tool transformer).

An alternative method is to make it yourself. This technology is described in detail in an article about the Moment electric soldering iron.

The only difference is that there is no short-circuited secondary winding. It can be wound not with a solid bar, but with a parallel set of available wires with a cross-section of 2.5÷3 mm square. A minimum voltage of about 12 volts will be sufficient for welding copper, but it is advisable to increase it by 2–3 times.

Design of a device for welding twists

Such a device is not difficult to make with your own hands. It greatly simplifies the work and makes it safer.

The carbon electrode is mounted on a fixed metal base.

The twisted wire is simply inserted into the thumb clamp of a movable metal arm and pressed against a graphite flux electrode (borax). Voltage is briefly applied to the transformer to carry out welding. The wires are allowed to cool right inside the electrode recess.

You will need to experiment to determine the welding time by trial and error, using scrap pieces of wire to create additional twist.

Powerful DC Regulator

It is manufactured in a separate body, consisting of two blocks:

They are connected by wires to each other and leads from the secondary winding of a separate power voltage transformer, as well as welding electrodes.

This regulator produces rectified current, which can be used for welding and other purposes, for example, charging batteries, parallel powering the starter when starting a car engine, or performing other work.

The structure is easy to assemble using the hinged method. Even in this case, you can achieve its small size.

The regulator receives power from the secondary winding of the power transformer. The input voltage can be within 50÷90 volts.

The electronic unit

The work is based on the circuit of a phase-pulse signal generator made of two bipolar transistors of direct and reverse conduction (pnp and npn type).

The position of the potentiometer R2 slider affects the charging rate of capacitor C1 to a voltage of 6.9 volts. When it increases, transistors VT1 and VT2 open. Through them, the discharge of the capacitor begins on winding I of transformer T1 (pulse type).

This discharge pulse, through the secondary windings II and III, enters the control electrode of the power thyristor VS-3 or VS-4, opens it with the corresponding direction of the half-wave of the sinusoidal voltage harmonic.

Thyristors VS-1 and VS-2 operate as intermediate control current amplifiers for the power circuit. The fact is that three-winding transformers of the TI-3÷TI-5 series are used as pulse ones. In all three windings they have the same transformation ratio (1:1:1). The pulse current they create is small; it needs to be increased.

The same issue can be solved differently: assemble a pulse voltage transformer on ferrites with an increased transformation ratio in the secondary windings, achieving a current value sufficient to control the output stage of the main thyristors.

Output power block

The work is based on an asymmetrical bridge design. In it, thyristors VS-3 and VS-4 operate in the same phase. They are capable of normally withstanding current up to 160 amperes, directing it through a carbon electrode. Arms with diodes VD6, VD7 are used as a buffer.

If no errors are made during installation, the regulator operates immediately without additional adjustment.

To consolidate the material, I recommend watching Tatyana Avramenko’s video “Welding copper wires.” Just be critical of the methods of cutting cores and insulating twists shown by the author.

Now it’s convenient for you to ask questions in the comments and share this material with your friends on social networks.

Source: https://HouseDiz.ru/kak-sdelat-transformator-dlya-svarki-provodov-svoimi-rukami-i-rabotat-im/

How to weld twists

When carrying out electrical installation work, in particular when installing, repairing or replacing electrical wiring, it is impossible to do without wire connections. They are always found in junction boxes; they are used when replacing a faulty section of the circuit.

One type of reliable permanent connection is twist welding, when the wires are first twisted and then welded.

Connection Features

There are quite a few ways to connect wires - using screw and self-clamping terminals, crimp sleeves, a bolt and nut (through a washer). But most often, the ends of the wires are connected by twisting, that is, they are simply twisted.

All of the above methods have one significant drawback. Even if the rules and technology of work are followed, the area of ​​the contact zone of two conductors turns out to be less than the working cross-section of the core.

At a sufficiently high load (not exceeding, however, the permissible load), the contact area will heat up. Which can lead to insulation melting, short circuit, or fire.

Twists have an advantage over other types of connections, since twists can increase the contact area of ​​the wires. To do this, it is enough to solder the ends of the cores in a twist or weld them.

Soldering connections are quite labor intensive. And if you consider that distribution boxes, as a rule, are located at a level of 2.3-2.5 meters from the floor, it is very inconvenient to carry out the work.

After all, in addition to a soldering iron, you need to have solder with you, and sometimes also flux. And all this is at its best. In addition, in order for the connection to be of high quality, it must be heated for quite a long time, which also does not speed up the work process.

Advantages of the method

Twist welding is a more technologically advanced type of connection. It is faster and does not require any filler material. The melted ends of twisted wires form a strong connection that is not subject to electrochemical corrosion.

Welding requires additional equipment, and this is the only drawback. If you do not have a special welding machine for welding twists, you can use an inverter welding machine, or you can make such a machine yourself.

A special feature of twist welding is that it is carried out with a carbon non-consumable electrode, which for convenience is better sharpened to a cone.

Using an inverter device

To weld twists, you can use an inverter-type welding machine. The advantages of such devices are that, with a relatively low weight, they have significant welding power, while consuming a small amount of electricity.

This allows you to use inverter devices by connecting them to a household AC network without fear of voltage surges and drops. Inverters provide excellent output current parameters, which allows you to maintain an even and powerful arc.

The current value may vary depending on the core material and cross-section. Since aluminum cables with aluminum conductors are currently not used for internal electrical wiring, the parameters of the welding machine can be selected based on the requirements for welding copper conductors.

Example requirements are:

• for welding two wires with a cross-section of 1.5 mm², a current value of 70-75 A is required;
• the twisting of three such wires is welded with a current of 80-90 A;
• two or three wires with a cross-section of 2.5 mm² need to be welded with a current of 80-100 A;
• three or four of the same wires are connected using a current of 100-120 A.

Due to the high cost of inverter welding machines, it is unprofitable to purchase them to perform only twist welding. If you use some parts that can be easily purchased or removed from old electrical appliances, making a device for welding twists with your own hands will not be difficult.

Homemade apparatus

The main component when assembling a machine for twist welding is a transformer with a power of at least 600 W, with an output voltage of 12-36 V. It must provide such voltage when connecting a supply voltage of 220-230 V.

When assembling the device, a durable metal case of suitable dimensions is required, in which it is necessary to provide the possibility of installing a fuse or circuit breaker with a rating of 16 A.

The supply voltage to the transformer must be supplied by a cable with copper conductors and a cross-section of at least 1.5 mm². It is better to use a KG 3x1.5 cable with rubber insulation for this. The device body and the transformer core must be connected to the grounding conductor.

To connect the transformer to the ground contact and the holder, two wires with a cross-section of 10.0 mm² are used, for example KG 1x10. Their length should be as short as possible to avoid current losses. The holder can be used from any used welding machine.

A carbon electrode can be made by disassembling an old 373 battery. The core, also known as the positive electrode, is perfect for this purpose.

If you cannot get such a core, you can purchase carbon brushes for electric motors used in electrical appliances or power tools at the store. The brush is clamped into the holder and sharpened into a cone shape.

It is convenient to use pliers as a ground, connecting one of their handles to the transformer with a KG 1x10 wire. After this, the handles must be insulated. This device will allow you to comfortably hold the twist while welding. At the same time, the pliers will also act as a heat sink.

Security measures

Welding twists with a homemade device is not inferior in efficiency to welding with an inverter machine. When carrying out work, it is necessary to take into account the harmful factors that appear during conventional welding.

It is necessary to use shields with light filters to protect against ultraviolet radiation, gloves and clothing made of fireproof material . In addition, it is necessary to ensure compliance with fire safety measures.

Proper use of equipment and adherence to technology, as well as safety measures when working with welding, will allow you to obtain a reliable connection of cables. Ultimately, the reliability of all electrical wiring increases and the period of its trouble-free use increases.

Source: https://svaring.com/welding/detali/svarka-skrutok

Do-it-yourself welding of copper and aluminum wires

The provisions of the PUE recommend welding of wires as one of the most reliable methods of connecting them. The advantages of using this method significantly outweigh the few disadvantages, which makes it popular among home craftsmen and professional electricians.

Pros and cons of welding, its varieties

The advantages of connecting wires by welding are the absence of transition resistance, which is always present in twisted or bolted connections. This is especially true when laying wiring for powerful devices.

The disadvantages are the need to buy or make your own welding machine designed for twisting.

Welding work requires some skills, so the electrician who will weld the strands needs to learn at least the basics of this craft.

When performing electrical installation work in production, various types of welding are used: standard, arc spot, plasma, torsion, electron beam, ultrasonic, or various combinations thereof. For domestic use, electricians most often use a device for spot and arc welding, which operates on carbon or graphite electrodes.

This solution allows you to obtain good quality connections at a minimum cost of the necessary devices and components.

When making a wire welding machine, most attention should be paid to the following characteristics of the device:

• The current strength that the device can produce. Ideally this is a variable value.
• The voltage produced by the device is sufficient to cause an electric arc - usually 12-32 Volts.
• What kind of current does the welder use - alternating or direct? If you have experience in such work, you can use variable, but for beginners it is strongly recommended to start with constant.

Since welding different metals requires different currents and voltages, universal welding machines can necessarily adjust these values.

In addition, when joining different materials, you may need special fluxes that will protect the metal from oxidation or the penetration of gases from the air into it.

Most universal-purpose welding machines are quite bulky and heavy, but for small welding jobs you can find inverter welders for a relatively low price that are ideal for welding wires.

If you are welding copper wires that are used in home wiring, there is no need to use very high current and voltage, so it is possible to use small-sized welding machines that fit into a standard tool case.

The principle of operation of arc welding - device diagram

Since welding requires a large current, the basis of any welding machine is a step-down transformer - a loss in voltage is always accompanied by a gain in current and vice versa.

A standard diode bridge is used to convert alternating current into direct current, and a capacitor is used to smooth out ripples.

A noticeable disadvantage of using a direct current device is that the diodes and capacitor used are rather large and they significantly increase the weight of the welding machine, which is initially made portable.

Experts also recommend installing additional resistance at the input or output of the diode bridge, since diodes “do not like” a short circuit in its pure form.

Many craftsmen manually assemble a welding machine for welding copper wires, which produces an arc from alternating current and use them successfully. Therefore, it is impossible to say unequivocally that it is necessary to use a direct current device - everyone chooses the necessary model according to their skills. If an AC welding machine is manually assembled, then the diode bridge and capacitor are simply thrown out of the circuit.

A necessary skill that you will have to master to use an AC welding machine is to learn “by eye” to determine how long you should hold the ignited arc of the electric discharge so that the end of the twist heats up and fusions.

The most common way to make a negative contact for welding is with old pliers that hold the wires.

For the phase, take a clamp that can hold the graphite rod. The design of the clamp can be very diverse - from a screw connection to the so-called “crocodiles”, both home-made and factory-made. To connect to the welding machine itself, cables with a cross-section of about 10 mm² are used.

Despite the fact that a device assembled in an industrial environment is an order of magnitude more expensive than a homemade one, its price is not exorbitant and allows you to purchase such a welding machine even on a limited budget. The advantages of its use are obvious - it is a precisely calculated design with a current regulator, which allows you to work with different types of metals and the number of wires being welded.

Nuances of the wire welding process

With the necessary skills, welding conductors does not take much time, but in order to obtain a high-quality connection, it is strongly recommended that you first practice on separate pieces of cables. Moreover, this must be done if you are using a twist welding machine that works with alternating current - you need to get used to the power of such a device. The whole process is clearly shown in the following video:

Step by step everything looks like this:

• Stripping wires. A feature of welding is the need to expose the wire cores to a length of 60-80 mm. Less is impossible, since during welding the wire heats up quite strongly and the insulation will melt.
• Twisting wires. It would seem that you can simply fold the wires and weld - a drop will still form at the end, which will connect everything together. The problem with this connection method may be the fragility of the wires - it is not a fact that it will occur, but for some reasons, the droplet resulting from welding with a carbon electrode acquires a spongy structure and is susceptible to fracture. This does not affect conductivity, but if the wires are not twisted, they may break.

• Trimming the twist. The fluffy ends of the veins must be trimmed to get an even cut. Then the arc during welding will evenly heat the entire surface of the twist and the drop will be even.

• Welding. The twist is grabbed with pliers and a graphite electrode is brought to its tip until an electric arc occurs. It must be maintained until the ends of the wires fuse, forming a smooth drop. The next twist is welded after the previous one has cooled.

If the arc does not appear, then the power of the transformer is insufficient or the wires to the electrode holders are too long (their resistance prevents sufficient current from being obtained).

The optimal option for the length of the wires is 2.5-3.5 meters, but in the first case you will have to place the welding machine on a stand for ease of operation.

• Twist insulation. The best option in terms of speed here would be to use heat-shrinkable casings, but to warm them up you will additionally need a hair dryer or a good lighter. There is also no hindrance to using ordinary electrical tape - except that it will take a little longer.
• Welding copper and aluminum wires. In general, it is performed in exactly the same way as a regular one - the only difference is in the preparation of the wires. The copper core remains straight, and the aluminum core is wrapped around it. Then flux is applied to the aluminum, which, when heated, removes the oxide film from this metal, and welding can begin.

But if you follow the instructions of the PUE, then in domestic conditions you are unlikely to have to work with aluminum wires, since the use of such cables with a cross-section of less than 16 mm² is prohibited for laying electrical wiring.

Welding wires with an inverter

The use of such a device is most preferable, since welding copper and aluminum wires with an inverter is much easier than with homemade welding machines. This is a universal device, the current in which is adjustable in the range of up to 160 Amperes. In addition to the fact that it can weld twists, it allows you to work with metal up to 5 mm thick - for home use this power is usually more than enough.

Typically, such a device is the prerogative of professionals who are constantly faced with welding work, but at the same time it can be safely recommended to beginners who are just mastering welding strands with their own hands. The “hot start” function, protection against electrode sticking and the ability to work even during voltage surges will allow a novice welder to quickly master the basics of this craft, and a professional will always enjoy working with a good tool.

If the device allows you to regulate the voltage and current, then “by eye” what values ​​to set can be determined by the diameter of the wires and their number.

Briefly about the main thing

Welding the ends of twisted wires significantly improves the conductivity of these contacts, and therefore the characteristics of the network as a whole.

Welding machines that allow spot welding are commercially available and are also simple enough in design to make them yourself. But in the second case, simpler devices that produce alternating current are most often assembled - such devices require certain operating skills.

In practice, there is not much difference in using one device or another - if the master is experienced enough, the result will be good in any case.

Source: https://YaElectrik.ru/elektroprovodka/svarka-provodov

Types of welding machines

Today, there are many devices that can ensure trouble-free work for electrical installers. Some of them are quite expensive, others are free fruits of engineering.

The following types of welding machines are used for welding copper strands:

1. Professional equipment developed and produced by industry. Imported and Russian production. For example, an industrial machine for welding twists TS-700.
2. Inverters. Straighteners capable of welding ferrous and non-ferrous metals.
3. Self-taught welders.

Homemade machine for welding twists

When a person thinks about buying such equipment, he begins to wonder whether it is possible to make it himself. Indeed, many electricians who have extensive experience in handling electrical equipment have brought to life the idea of ​​​​making a machine for welding strands with their own hands.

Basic concepts:

1. Current strength, indicated in amperes.
2. The voltage, measured in volts, applied to the welding machine.
3. Type of current. There is direct and alternating current required by welding units.

Extensive work experience told them to use a transformer from a broken microwave. Such a unit is capable of producing 4 kW.

Main stages of work:

• Carefully disassemble the microwave oven.
• Free the transformer from all unnecessary things.
• Upgrade the transformer for the required purpose.

Disassembling a transformer requires special attention. It is better to choose it with a power from 700V to 1000V. The welding seam can be cut with a grinder with a thin circle. From the extracted microwave material, the magnetic circuit, the transformer itself, which has a thicker cross-section of the primary winding wire and a small number of turns, is useful.

Modernization

The primary winding suits us perfectly. The next thing to do is throw out the secondary. An ordinary chisel and a metalworking tool will help us remove it. Having carefully removed and cleaned the secondary winding, you need to look at the magnetic circuit; if there are shunts, they will have to be dismantled. The secondary winding of a new machine for welding copper strands should be made with a cross-section of 15-20 mm². Approximately 12-13 turns.

If it is not possible to find the required copper core, you can use twisting, that is, several laid parallel wires. The main condition for such twisting is the final result - you should get a tire of 15-20 mm².

Fabric insulation is suitable for insulation. Having made and insulated the copper bus, we will carefully manufacture the secondary winding of the transformer. The measured voltage should be from 9 to 36 volts.

Having thus modernized the transformer of the machine for welding twists, we proceed to the manufacture of the remaining elements of the welding machine. To do this, you need to make sure that some important conditions are met. The wires from the modernized transformer to the machine for welding twisted wires must have a cross-section no less than the cross-section of the secondary winding, that is, 15-20 mm². It is necessary to take into account that during the welding process the wires become very hot. Copper heats up quickly.

Holder and weight of the device

When working at height, the convenience of holders for welding wires is of great importance.

The optimal solution is to use carbon electrodes. Some people use carbon electrode rods from batteries in homemade welding machines for welding twists.

Many people use simple brass “crocodiles” to hold the graphite electrodes from the battery. But as mentioned above, the heating of wire elements and various devices during the welding process is large. “Crocodiles”, when heated and charred, lose their intended purpose. The material becomes soft and cannot hold the electrode.

Carbon Electrode Application Techniques

Let's consider one of the most rational ways to use a carbon electrode. A carbon brush is taken, in which several recesses are pre-drilled for welding copper strands of various sections. The brush must be taken from a high-power electric motor.

The graphite brushes have leads to which you can successfully solder wires from a twist welding machine.

To make it convenient to hold such a brush at a height, you need a holder. You'll have to make a homemade clamp to hold it in place. Attach a handle to it. You can take the handle of a chisel or file. Modern chisels use material that does not allow current to pass through, which is very good for the job. The holder made in this form is very convenient. The twist inserted into the drilled recess is perfectly welded and has a neat appearance.

Making a second welding holder

The second wire from a homemade twist welding machine can be connected very well with pliers. The connection must be fixed to the handle of the pliers using soldering. There are various methods for soldering steel and copper.

It’s easier to use a copper tube, into the end of which the second wire of our homemade product is inserted and soldered. The tube is also soldered to the pliers. This design is very convenient and reliable. For efficient operation, it is good to drill a couple of holes in the jaws of the pliers for twisting wires of different sections.

The maximum length of wires is no more than 3 meters. Otherwise, resistance increases.

How to make a welding machine switch?

One of the conditions for convenience in work is the direct contact of the twisted wires with the ground from the welding equipment and the holder.

Working with always-on equipment requires a lot of experience. When the mass and the holder come into contact, lightning-fast contact occurs, which is not very good when working from a stepladder or ladder.

People who were able to make a welding machine for welding twists with their own hands solved this problem simply. They installed the switch connected to the primary winding on the handle of the holder.

When the power is turned off, the twisted wire is quietly installed in the recess on the brush. After the twist is installed, voltage is applied and the welding mode occurs. Having made the twist, the power is turned off and time is given for the twist to cool. The work is safe and convenient.

The pliers, in addition to serving as a holder, play the role of a heat sink. The temperature generated during the welding process heats the pliers, thereby preventing the wire going to the transformer from overheating. Working with such equipment is no worse than working with a TS machine for welding twists. It is advisable not to forget to install two single-pole circuit breakers in the homemade product, which protect the windings from overload.

Device case

The casing for your homemade welding machine for welding twisted wires can be made from various failed devices and equipment located in the casing. At home or in the garage, there is sure to be an old household appliance that can be used for something truly worthwhile.

For this purpose, the housing of an oscilloscope, computer, and other equipment of suitable size is suitable, preferably with slots in the housing for ventilation.

It is better to make the base for a homemade welding machine from textolite or getinax. Having thus removed our homemade welding unit into the housing, we will make a device for the belt, which is necessary for work on the construction site. Hanging your welding device on your shoulder, it is convenient to work with it on a stepladder.

What do you need to know about preparing wires for twisting?

The wires must be stripped of about seven centimeters of insulation. This is done so that it does not melt during the twist welding process. You also need to remember to leave wires of sufficient length in junction boxes when making electrical installations. After twisting the wires, remove their excess length using side cutters. By biting off the excess, you can get a neat twist, convenient for welding, and after welding the twists, you can have a high-quality and reliable connection.

At this stage, we can assume that the homemade device for welding twists is ready. All that remains is to test it in action.

Conclusion

Using the TS-700 2 twist welding machine is, of course, convenient. Light weight of 4.5 kilograms in a secure belt case ensures its mobility.

A reliable electrode that can withstand up to 1 thousand welding pulses makes it a desirable tool.

But the average cost of 10 thousand rubles is not something every electrician can handle. So why not pack a homemade welding machine in a protective casing and equip it with a belt? It will be as easy to use as branded welding equipment.

Any person with a little knowledge of electrical engineering can make a homemade machine for welding copper strands using these recommendations. The cost of homemade equipment is lower than factory analogues. However, the reliability and quality of the welding work performed will be high, which has already been recorded many times.

Source: https://FB.ru/article/320245/apparat-dlya-svarki-skrutok-svoimi-rukami

Twist welding machine

When replacing wiring, it is better to weld or solder all twists of copper wires; I have even seen such welding on aluminum wires in the wiring of a house built in 1960. Even then, builders knew about welding wires. Read on to learn how to make a machine for welding copper strands with your own hands.

Wago terminals

Many will probably say: What are Wago-type terminals for? It's the 21st century!

I answer right away: I installed these “super terminals” when replacing the wiring in the apartment, and when I turned on the electric kettle, such a terminal melted, I didn’t like it very much, I even disassembled one such terminal and saw that the contact there was very thin.

Therefore, sometimes the good old twist will be more reliable than all this modern “good”!

At one time, of course, there were good dead-end terminals - you insert a twist into it and tighten it with a screw - it turns out to be insulated and firmly fixed - an awesome thing, but now they have completely disappeared from sale. It's a shame  

Source: https://evmaster.net/svarka-mednyx-skrutok

Do-it-yourself transformer for welding copper wires: step-by-step instructions

Wires can be connected using different methods. Their differences lie in the dynamics of operation, the quality of contacts and the ability to operate continuously under heavy network loads. And the most reliable method is twisting and welding. But it requires a special device. Do-it-yourself transformer for welding copper wires

Requirements for a transformer for welding

This should be an AC device with an approximate parameter of 400 -600 W. The output winding must have a voltage from 9 to 36 V.

Carbon or graphite electrodes are used to connect copper wires or strands.

A copper heat sink clamp with a large area must be used. And the more solid it is, the better.

The unit must also be equipped with a current control option. The welding itself lasts a few seconds. To achieve the best effect, the cross-section and number of cores in the wire should be taken into account.

The following shows the relationship between these indicators and the required current power.

Section (mm)	Number of wires made of copper	Current (A)
1,5	2	70
1,5	3	80
2,5	2	100
2,5	4	120

Varieties

Inverter devices are the most popular. They are easy to purchase in the store. They have solid functionality and a range of capabilities.

The work is greatly facilitated by the “hot start” option. It protects the device from sticking and power surges. Thanks to a current of up to 160 A, you can weld metal with a density of up to 5 mm. This is enough for everyday tasks.

Good demand has been noted for such models as:

• Resanta SAI-160.
• QUATTRO ELEMENTI A
• PFTRIOTMax Welder DC-200 C

Transformers created by their own efforts can perform different types of welding:

• Dugovaya. Such a device is most often created by hand. It is characterized by a simple design, which, in addition to the transformer, consists of: a current controller, an electrode clamp, and a ground clamp.

In home-made units, a transformer is usually installed that has a toroidal and U-like magnetic circuit, around which the copper wire windings are concentrated . Depending on the functional qualities, the density of the wire on them also changes.

• Spot. The welding area is heated by two copper electrodes and is subjected to high pressure. The design contains capacitors. The transformer has copper contacts. The components to be welded are concentrated between them. The power of transformers here is inferior to point 1. They also have a U-like core.



Whatever model you plan to create, you need to know its characteristics and how they can be varied.

How to assemble a transformer for welding copper wires with your own hands

If for some reason purchasing a device is not an acceptable option, you can build this equipment yourself. The basis for it is an old transformer.

Preparation of tools and materials

To create the planned device you will need the following arsenal:

• Transformer.
• Finished box or casing.
• Electrical cable.
• Pliers.
• Device for holding the electrode.
• Carbon electrode.
• Automatic or semi-automatic devices.

To make step 6, you can use the core of a massive round battery or a large carbon brush.

It is necessary to assemble a homemade device only if you have good knowledge of the circuitry and operation of such devices.

As a base, you can use transformers from unused old TV sets, microwave ovens, etc. The base power should be 200 - 500 W.

Build process

It goes through painstakingly, the turns are scrupulously counted. The following is an example of creating a device with a P-like core. This process is much simpler than toroidal modification structures.

Stages of work

Frames for windings. They are created from textolite plates, from which elements for a pair of boxes are cut. Each box has two top lids with slots into which four walls are placed. The area of ​​the slots inside is identical to the cross-section of the core. At the same time, the dimensions of the walls of the box increase insignificantly.

• Insulation of frames with heat-resistant material.
• Winding windings.

The wires for them must have heat-resistant glass insulation. After winding one layer, insulate it and make the next one. Taps are created on a certain number of skeins. In the final phase, the top insulation is wound. The ends of the wires are pulled through holes made in the topmost plate. Copper screws are then secured to these ends.

• Assembly and lamination of magnetic wire. Here, iron plates from outdated transformers are used. Their thickness is 1 mm. They are assembled into a monolithic structure. At the end, all windings are tested for defects by a tester.
• Creation of a diode bridge. Diodes B200 or KBPC5010 are used. Each of them is designed to operate with a load of 50 A. If your device has a parameter of 180 A, you need 4 such diodes. They are fixed to the radiator. Their connection to the windings is parallel.
• Housing assembly. Place a transformer there.