How to make a pulse soldering iron

Pulse soldering iron: how it works, diagram

Carrying out work on soldering circuits and wires in home and industrial devices involves the use of soldering irons. They are found in several variations, which differ in operating principle and power. They are also used for various purposes. One of the options, suitable for beginners and professionals, is a pulse soldering iron.

Device Description

This option is a soldering iron, the heating of which occurs pulsed. This lies in the fact that voltage acts on the tip only at the moment of interaction of the soldering iron with the soldering object. This reduces energy costs and increases device life and efficiency.

Pulse electric soldering iron

Operating principle

The design and principle of operation of this type of device is based on a simple physical effect in which the conductor is heated when a large current flows.

When the device is turned on by pressing a button, the primary circuit of the input signal source is turned off, the transformer switches to low voltage on the secondary winding. In this case, there is a current in the output circuit to quickly heat the tip.

When the button is released, the circuit turns off, the current stops flowing and heating stops.

At a low voltage of about 2 volts, the current in the operating circuit reaches 25-50 amperes. The secondary winding of the transformer must be wound with wires, and the cross-section of the winding must be several times larger than the cross-section of the tip.

The same rule must be followed for the conductive busbar that connects the end of the spike to the secondary winding.
This will prevent energy wasted on heating. Switching power supplies are replacing transformer power supplies, and their popularity is slowly growing.

They allow you to significantly reduce the weight and size of equipment with the same performance.

Characteristics

One of the most popular on the market is the STING pulse soldering iron model. This device has the following characteristics:

• Supply voltage 145-270 V
• Voltage frequency 50-60 Hz
• Power consumption 30-125 W
• The heating time of the tip reaches operating temperature is 1.5-6.0 seconds.
• Maximum temperature of the working area St 500 °C
• IP 2.0 protection rating
• Dimensions 176 × 130 × 26 mm.
• Cable network 1 m long
• Weight 0.18 kg

Soldering iron STING

Advantages and disadvantages

A pulse soldering iron will have advantages over other types of soldering irons:

• Low power consumption. Devices of this type consume energy only during the direct process of mounting the board.
• Safety. When it is not working, the tip will immediately cool down, and such equipment will not burn out, ignite anything on the table or melt the insulation.
• Ease of use, accessibility to repair and maintenance. The tip can be replaced in a few minutes.
• In addition, the sting can have any shape. This is useful where the board or wires are difficult to reach.

Along with these advantages, this type of device has one drawback: this soldering iron is heavy, large in size and inconvenient to use during long-term use.

Important: To make work easier, the soldering iron is powered from a separate pulse source, which is located in a separate housing.

Comparison of conventional and pulsed devices

Device

A pulse soldering iron is relatively simple in design. It includes:

• Sting. It is a V-shaped copper wire, which is fixed in the handle and has a thickness of 1-3 mm.
• Power unit. Supplies low voltage current to the working element.
• Lever.
• A button that is used to start the device.
• Network cable with plug.
• Backlight or LEDs illuminate the work area (not found in all models, but this is a very convenient feature).

The most complex component is the power supply. It converts the main voltage 220 V, 50 Hz into low voltage high frequency (20-40 kHz). The input circuit is connected to the network cable through the power button, and the contact on the tip is connected to the output circuit. Pulse soldering irons have various options and voltage supply circuits.

The voltage supply device can be built into the handle. The transformer, mounted on the outer casing, is heavy and large in size. Prolonged use can greatly fatigue the worker. In some models, the current source is a stand-alone unit. This improves the safety and usability of the device.

In this case, only the power button is installed in the handle.

Pulse device device

DIY making

Step-by-step instructions for making your own pulse soldering iron on transformers:

1. First you need to select a transformer suitable for this purpose. In any case, power is supplied from old electronic devices with a power of 50-150 W.
2. Carefully disassemble the coil.

Important: this must be done with extreme caution, since this will be the main part of the device.

1. Next, you need to make and place copper wiring with a cross-section of at least 20 mm on the primary coil. One skein is enough, but you must leave a free end of at least 15 cm in length.
2. After this, you need to insulate the coils with fiberglass or heat shrink tubing.
3. Connect a V-shaped copper wire 1.5-2 mm thick to the end of the bus (the cross-section is selected experimentally).
4. A handle is cut out of wood or fabric and the power button and transformer are fixed in it.
5. The network cable is connected to the primary winding.

Homemade device

Also, the soldering iron can be assembled from components obtained from energy-saving lamps. For this you will need:

• Cord with plug.
• Fastening.
• Wires.
• Copper wire (thickness approximately 2-3 millimeters).
• A transformer that would lower the voltage from 220 V to the required one.
• A converter borrowed from a fluorescent lamp.

Pulse soldering iron from an energy-saving lamp circuit diagram

A pulse electric soldering iron is an option for beginners and professionals, which saves energy and ensures efficient and high-quality work. Making it at home using a transformer or a light bulb is something that almost anyone can do.

Source: https://rusenergetics.ru/instrumenty/impulsniy-payalnik

Pulse soldering iron: principle of operation, circuit diagram and DIY production

When you need to quickly solder something, but don’t want to wait for the tip to warm up, a pulse soldering iron will come to your aid. Its main advantage is that it reaches operating temperature in 1-2 seconds. Of course, you can buy such a soldering iron in a store, but it will be much cheaper and more pleasant to assemble it yourself, especially if you have unnecessary radio parts lying around.

Any induction (pulse) soldering iron consists of a step-down transformer, a short-circuit button and a tip made of copper wire, 1-3 mm thick. In some designs, a power source and other elements are added to them.

This is what the circuit of a simple induction soldering iron looks like:

It should be noted that in this diagram the transformer has two secondary windings: one powers the lamp to illuminate the soldering area, and the other powers the tip.

A pulse and induction soldering iron are not the same thing. Pulse soldering irons are called induction soldering irons that incorporate a high-frequency voltage converter. The example device with a step-down transformer is not pulsed.

How the device works

The soldering iron works in this way: when you press the button, the voltage is supplied to the transformer, where it drops to 0.5-2 volts (accordingly, the current increases greatly) and goes to the tip, quickly heating it up. When you release the button, the tip also cools down quickly, so after releasing the button you need to quickly move it away from the part being soldered, otherwise it will be soldered to it.

Of course, a pulse soldering iron has differences from a regular one, among them there are both pros and cons. The advantages include quick heating and equally rapid cooling (the risk of getting a burn if you accidentally touch the tip is significantly reduced). Unfortunately, it has more disadvantages:

• greater weight and size, inability to accurately regulate temperature;
• the presence of an electrical potential on the tip, which can damage the electronic components being soldered - this drawback is absent in induction soldering irons with insulated tips;
• impossibility of long-term continuous operation (the standard operating mode for them is from 5 to 8 starts per 1 minute for an hour, then a break to cool down for 20 minutes).

Types of instruments

There are 4 main types of these devices. They can exist as separate species, but their characteristics can also be combined. Main types of soldering irons:

• network, operating at network frequency;
• with forced heating;
• pulse;
• with an isolated tip.

There are also pulse soldering irons with an insulated tip and forced heating. Incompatible types are mains and pulse soldering iron.

Pulse, in contrast to unregulated network, can already have power regulation through the use of a pulse converter that operates at high frequencies and can change power using the pulse-width modulation method. Due to the relatively small size of the converter, this type of induction soldering iron is the most compact of all.

Soldering irons with forced heating are devices that include a battery of powerful electrolytic capacitors connected in parallel to the tip and separated from it by switches or powerful field-effect transistors.

This afterburner works as follows: when the tip is turned off, the transistors open and the capacitor begins charging. After charging is complete they close. Then, when the tip turns on, the transistors open again, discharging the capacitors, and for a short time the power of the soldering iron increases several times.

This function makes it possible to solder massive elements with high heat capacity.

To eliminate the possibility of damage to microcircuits, insulated tips were invented. In them, the working surface of the tip is electrically isolated from the heater. Such tips are similar to ordinary soldering irons: the tip is a thick copper rod, on which several turns of large-section wire are wound. The rod is protected from contact with the wire by fiberglass wrapped around it.

Transformer device assembly

This type of soldering iron is the simplest. Therefore, it will not be difficult to assemble it.

To do this you will need the following components:

1. The core is from a ShP type transformer (if you can’t find it, you can use the P type, it’s worse, but it will also do).
2. Copper wire in varnish insulation with a cross section of 0.3 mm, for the primary winding.
3. Copper wire or bus with a cross-section of 12-15 mm, which will go to the secondary winding.
4. Copper wire, 2-3 squares, for making a sting.
5. 2 terminals for connecting it.
6. A switch in the form of a button that operates to close.
7. Any soldering iron case and power cord convenient for you.

Assembling an induction soldering iron with your own hands, diagram:

First you need to wind the primary (when winding it, be guided by the resistance - it should be about 40-50 Ohms, this is approximately 1500 turns), and this must be done carefully, the coil must be wound evenly, without bumps along the edges or in the center. Before winding, insulate the core in the area where the winding will be located.

After winding, wrap the primary winding with heat-resistant tape and begin winding the secondary. It should consist of one or two turns. Before winding it, insulate the core again; the winding itself does not need to be insulated; it plays the role of a radiator, dissipating the heat coming to it from the tip. That's it, the transformer is ready.

All that remains is to prepare the case by cutting holes in it for ventilation, terminals and a switch, then install all the parts in it and connect them as indicated in the diagram. After this, solder the network wire of the length you need and mount a plug at the end to connect to the network. Having assembled the case, plug your resulting device into a power outlet and check its operation. If it melts the solder and the tip does not burn from overheating, then everything is in order and you can safely use it.

Making a pulse variety

It is the most common of all. It's just as easy to assemble as the previous one.

List of spare parts required for its assembly:

1. Electronic transformer 12 volts for halogen lamps, power 60-90 watts.
2. Copper wire with a cross section of 3 mm, for the secondary winding and tip.
3. Closing button.
4. Terminals.
5. A piece of fiberglass for attaching terminals.
6. Power cord with plug.
7. Plastic water pipe, for use as a handle.

First, you need to slightly modify the halogen driver, namely, replace the secondary winding of the pulse transformer. To do this, disassemble it.

Inside it will look like this:

The required part is circled in red.

You need to carefully peel it off, then, having unsoldered the leads from the board, remove it completely. Then remove the factory secondary winding (it is located on top of the primary) and install your own, half a turn. Drill the board as shown in the photo:

After this, drill through the case so that the holes in the case and the board match. This is necessary for the convenience of bringing the ends of the secondary out.

Then solder and glue the transformer, maintaining the alignment of all existing holes, and assemble the case, having previously installed and soldered the button with the power cord. Then pass the secondary winding wire through the driver and bend it into a half ring.

All that remains is to connect the ends of the secondary with a piece of PCB with holes pre-drilled in it, and secure the terminals and tip to it, after which the assembly of the device can be considered complete.

The assembled device should look like this:

Side view:

Making a battery type mechanism

This option is more complicated than the previous ones; it is assembled not from blocks, but from individual radio components.

First let's look at the diagram

Let's make a list of the necessary components:

• 2 x 18650 batteries with built-in protection;
• 2 holders for 18650;
• 2 diodes;
• 2 resistors at 47 Ohm;
• 2 resistors at 5.6 kOhm;
• 1 capacitor 220 nF;
• 2 low-voltage (with a threshold switching voltage of 2-2.5 volts) field-effect transistors;
• 2 small radiators for cooling power transistors;
• High-current (10 A) button that operates to open.
• Ferrite sponge from a noise filter or any other small toroidal core for winding a pulse transformer.
• Smaller sized toroidal core for inductor winding.
• 2 terminals for connecting the tip.
• A piece of fiberglass for attaching terminals.
• A piece of foil fiberglass for making a board.

This is what the board layout should look like:

Link to gerber file with layout (open in Sprint-layout program): yadi.sk/d/SM1st1Lu3SaR3L

The circuit of this step-down converter does not contain a PWM controller, but is built on the basis of a symmetrical self-oscillator, which significantly reduces the complexity of the assembly and the size of the future soldering iron.

Before you begin assembling it, you need to assemble a pulse transformer and inductor , and also make a board (or use a breadboard).

The primary winding consists of six turns of wire with a cross-section of 3 mm and has a midpoint. Since such a thick wire will be difficult to wind around a small core, we recommend using six wire strands in varnish insulation, with a cross-section of 0.5 mm.

To begin, take two pieces of wire of the same length, fold them together and connect the 2 ends (after assembling the transformer they will become the middle point), leave the other two free.

Pass the common end into the core, and spread the rest and make three turns in different directions. More precisely indicated in the photo:

The secondary winding is much easier to assemble. It consists of 1 turn of wire with a cross section of 7 mm. To wind it, we recommend using 7 wires with a cross-section of 1 mm, twisted together. Before assembling the secondary, do not forget to wrap the wire with heat-resistant insulation (thermal tape, fluoroplastic or fiberglass tube). The transformer is ready.

Next, you should start throttling. It contains 13 turns wound with wire with a cross section of 1.5 mm. For winding, use a wire in varnish insulation. After assembling the inductor and making the printed circuit board, proceed to installing the entire circuit. After assembly, do not forget to glue the radiators to the transistors. As a result, it should look like what is shown in the photo:

After assembling the circuit, connect the tip to it (made from copper wire with a cross-section of 3 mm) and check the functionality of the soldering iron. If everything is in order, start assembling it into the case; before doing this, do not forget to glue the battery holders together and solder them to the board. The batteries are connected in parallel.

You should get this result:

​The rated power of the resulting soldering iron is 40 watts, the operating time on one charge is 1 hour, 20 minutes (when using normal batteries). The device is not intended for long-term operation; its scope of application is urgent repair of something necessary when the power is cut off at your home or if you are far from civilization. This soldering iron is also suitable for installers and repairmen of low-current equipment.

Its operating mode is as follows: it works for 10 minutes and cools down for the same amount of time. No more than 7 starts per minute are allowed.

Source: https://220v.guru/fizicheskie-ponyatiya-i-pribory/payalniki/sobiraem-impulsnyy-payalnik-svoimi-rukami-po-sheme.html

DIY pulse soldering iron circuit

In electrical engineering, during electrical installation, and more often in electronics, it is often necessary to firmly fix conductors, semiconductor parts or microcircuits to each other or to the board. This is usually done by soldering using a soldering iron. In the process, a low-melting metal is briefly heated to a liquid state, which allows for reliable, high-quality and durable fixation.

Pulse soldering iron: description

Depending on the type of work, soldering irons of various designs, devices and power can be used, from induction to ultrasonic. An ordinary factory soldering iron, which is constantly in a heated state, is good in its efficiency, but has some disadvantages.

For example, the soldering process itself takes very little time in relation to the entire process. After all, you need to clean and prepare the surfaces to be soldered. And all this time the soldering iron is on.

And this leads not only to wasted energy, but also to rapid wear and tear of the device itself.

To prevent the soldering iron from being constantly in working order during downtime, we came up with a pulse soldering iron that performs its function perfectly and, at the same time, is not constantly heated. It was precisely because of its ability to consume electricity in pulses that it was named so . The main differences between a pulse soldering iron and a regular one:

• Heating method;
• High heating rate to operating temperature;
• Low energy consumption;
• Possibility of power control.

Operating principle of the device

The pulse soldering tool has a fairly simple design. The heating element is a U-shaped wire bent from 1 to 3 mm, depending on the degree of work being performed. Direct heating of the tip occurs due to the fact that a current of minimum operating voltage, but of large magnitude, passes through it. This causes the principle of short circuit or so-called spot welding.

A low-power high-frequency step-down transformer and converter built into the housing, which produces electric current with a frequency of 18 to 40 kHz, helps to achieve a similar effect. At the ends of the secondary winding there are current collectors, on which the sting is fixed.

Making a product with your own hands

Of course, it is quite possible to buy a “pulse” and successfully use the factory version. However, there are two disadvantages that speak in favor of homemade analogues:

1. Low quality Chinese-made instruments on the shelves. Although at a reasonable price.
2. Too expensive “pulse devices” from well-known brands.

In order to make a soldering iron with your own hands, we will need:

• Power low-power transformer;
• Copper wire 1−3 mm for the tip;
• Copper bus;
• Handle material.

When we have everything we need prepared, we can start creating a pulse soldering iron with our own hands, a simple diagram of which looks like this:

The only thing we have to do is change the transformer a little, which can be removed from some old electrical equipment.

Now the transformer needs to be deprived of the winding, but this should be done carefully, since it will be useful to us later. Next, we wind the primary winding manually or by machine - there should be 1300 turns. The secondary winding is made from a busbar in one turn. For insulation you will need fiberglass or heat shrink. All that remains is to make the handle. Any material with dielectric properties is suitable for this.

Of course, you need to remember about the heating part. Here you will need copper wire from 1 to 3 mm thick, which must be bent like the English letter “U” and secured to the ends of the bus. The result is a home-made pulse-type soldering iron, which in its characteristics is not inferior to the factory analogue.

Soldering iron from an electronic transformer

The soldering iron we created is great for work, but it has several unpleasant disadvantages: high power consumption and excess weight, which is not always convenient. However, there is a solution to this problem - creating a soldering iron from an electronic transformer with your own hands.

To get started, we need the following components:

• electronic transformer;
• copper wire for the tip;
• LED indicators;
• on/off button;
• plastic box for the case;
• stand with dielectric characteristics.

Of course, in addition to everything else, we will also need a pulse soldering iron circuit:

We will need a switching power supply, which can be taken from a 40-watt fluorescent lamp. We will have to make an electronic transformer with our own hands, that is, modify one taken from a lamp to start it.

To do this, you need to remove the secondary winding and replace it with one or two turns of wire with a diameter of 1 mm. After the work has been done, all that remains is to place it all in the prepared case. For convenience, it is advisable to make the body in the form of a pistol with a handle, which will be much more convenient when working.

After this, a dielectric stand is mounted in place of the “trunk”, and the tip itself is fixed on it in the form of a loop. The tip itself is connected to the secondary winding. It is necessary to install a button and an LED in the handle of the “gun”, which will signal that it is turned on during operation. By pressing the button, the tip will heat up. It is not recommended to keep the device turned on for a long time, as the entire structure may fail.

Pulse made from an energy-saving lamp

If before this we used only part of the energy-saving lamp, then in this we will rely entirely on it. After all, in essence, this is a ready-made switching power supply. Thus, we will make a “pulse” from an energy-saving lamp according to the diagram (the parts to be removed are indicated in red):

After removing the “extra” parts, the places marked “A” and “A” should be connected using a jumper. By analogy with the previous method, the transformer needs to be redone. If there is not enough space for an extra winding, then you need to use an additional transformer, which is connected with the primary winding to the places indicated by the red lines in the figure:

The “pulse” made in this way is quite light and easy to work with. Moreover, it turns out to be practically free.

Microcircuit product of pulse principle

More complex in its design, but also more reliable, is a pulse soldering iron on a microcircuit. This device will have protection against overheating, which will automatically make it more durable and reliable.

In such devices, to protect the microcircuit from overheating, a special device is implemented, which eliminates the occurrence of breakdowns due to overheating. The role of the power supply here is played by a resistor, and the device itself must have an adjustable voltage input, variable from 0 to 15 V. An MLT resistor with a nominal value of 8 Ohms and a power of 0.5 kW ensures heating of the tip.

Read also: How to bend the edge of a metal sheet

To make such a resistor, one leg of the element is removed, and where it is fixed, a hole is drilled using an 11 mm drill. To avoid touching the internal cavity of the resistor bowl, when the tip is installed, the end is protected with mica. To indicate switching on, an LED is added to the circuit, which, when the button is pressed, signals the operation of the device.

The electric soldering irons described above are very convenient and practical to use. Instant heating allows soldering without wasting time. But you should understand that they are not suitable for all types of soldering. But in its field of application, it is a truly excellent assistant that can make the work of its owner easier. In addition, it is almost free, which is often important.

Pulse soldering irons have proven themselves to be a convenient, economical and safe tool for radio installers. Stores offer many models to suit every taste and budget.

The independent production of such a device can be dictated not so much by considerations of economy, but by the thirst for knowledge and the desire for self-realization of home craftsmen. In this article we will talk about the design and features of a pulse soldering iron and describe several ways to make it yourself.

The design of a soldering iron operating on the pulse principle

A pulse soldering iron is relatively simple. It consists of:

• The tip is the working body, it is a V-shaped piece of copper wire with a thickness of 1 to 3 millimeters, fixed in a holder.

Source: https://morflot.su/shema-impulsnogo-pajalnika-svoimi-rukami/

Design and operation of a high-frequency pulse soldering iron

It is impossible to do electrical engineering and electronics without a soldering iron. There are a lot of such devices sold in stores. You can buy a tool based on its power or the type of heating element. However, strong heating and a large tip area are not always required, especially when working with small parts and circuit boards, so there is a need to purchase or make a pulse soldering iron with your own hands.

Types of soldering irons

A heated tool that connects metal parts with special solder made from alloys based on lead, tin or copper is called a soldering iron. The parts that make up the soldering iron are simple and few in number:

• Electrical power cord with plug.
• Lever.
• A casing that protects the inside of the instrument.
• A heating element.
• Kernel.
• Tip, or sting.

To achieve maximum connection, copper is used to make the tip and rod.

One of the most common tools is a soldering iron with a nichrome spiral heater. Some models have a thermocouple sensor that turns off the tool when operating temperature is reached.

More modern are devices with a heater in the form of ceramic rods. They heat up faster, have greater ability to configure the necessary parameters and have a long service life.

A device with a ferromagnetic coating tip is heated by induced magnetic field currents. This device is called an induction soldering iron. The flame from gas combustion heats the tip in a gas soldering iron through a special nozzle. This device is autonomous, and refilling is possible from a regular gas cartridge.

Low-power, battery-powered soldering irons are also mobile and are used for repairing small parts. Ultrasonic tools are used for flux-free soldering using lead-free solders.

Pulse heating device

In order to assemble the circuit of an electronic device, soldering is required. But the components that make up the contents of such devices are very small, and the use of simple heating tools is limited. A pulse soldering iron is suitable for these purposes.

The small-diameter copper wire from which its tip is usually made has good thermal conductivity, and its small thickness allows it to reach the smallest elements. The low voltage used for heating does not require large energy costs. In addition, it is consumed exclusively during the soldering operation.

The main components of such a device are:

• High-frequency converter delivering frequency current from 18 to 40 kilohertz.
• A high-frequency step-down autotransformer, on the secondary winding of which there are current collectors for installing a tip, which is secured to them with screws for tight contact.
• Control circuit with microprocessor.

The latest devices of this type are equipped with various sensors and indicators, may have spot illumination of the soldering area and a handle made of heat-resistant non-slip plastic, reminiscent of a pistol. It is most convenient to operate with such a handle.

Low weight and dimensions ensure work with the smallest components of microboards of cell phones and tablet computers. And if there is a device for adjusting the heating level, then such a device will cope with larger objects and is also suitable for ordinary home soldering operations.

But some precautions must be taken: there are electronic components that react negatively to high frequency voltage applied to the tip.

Homemade equipment

There are a lot of electronics repair specialists, so the demand for pulse soldering irons is quite stable. But still, some try to make such a soldering iron from an electronic transformer with their own hands. The following reasons push them to do this:

• High cost of imported high-quality equipment.
• Poor quality products of Chinese origin.

The simplest high-frequency heater

For a person who is a little familiar with electrical engineering, making a tool is not difficult. For this you will need:

• Transformer.
• Copper shank and wire.
• Material for making a handle.

First you need to find a circuit for a pulse soldering iron. This is easy to do using the Internet.

The primary winding is connected to the power element, and the secondary winding is connected to the sting and signal lamp. This simplicity makes the device reliable and unpretentious in terms of voltage quality. Most inexpensive products are based on just such a scheme.

Manufacturing requires a small-sized power transformer. It can be taken from the power supply of any unnecessary or broken household appliance. Its circuit will be modernized. First you need to carefully open the transformer housing and get close to the winding, which needs to be carefully unwound. A new primary winding is wound from the wound wire at 1300 revolutions. This can be done manually or on a special winding machine.

Source: https://pochini.guru/instrument/ustroystvo-vyisokochastotnogo-impulsnogo-payalnika

Do-it-yourself pulse soldering iron: operating principles, manufacturing diagram

In many stores today you can buy a soldering iron for reasonable money. Yes, and you can assemble such a device with your own hands from parts that almost everyone has in their home. But it’s always more interesting to make something yourself than to buy something ready-made. In this article, we’ll look at what a pulse soldering iron is, the differences from a regular one, and the easiest way to make one yourself.

A pulse soldering iron is necessary for assembling (dismantling) elements of electrical and electronic products. The heating element is a tip, which is made of copper wire (diameter 1-3 mm) coated with other metals.

The tip is heated by passing a low voltage current through it. The soldering iron consumes little electricity, since current passes through the tip only during soldering. The device has a mains voltage converter with a frequency of 18−40 kHz.

The secondary (power) winding is connected to the current collectors of the tip.

The main difference between a pulsed soldering iron and a regular soldering iron is that it does not need to always be kept on to maintain the temperature. The tip is heated within a few seconds. It is precisely because of this that the device does not consume electricity most of the time.

Types of soldering irons:

1. Induction;
2. Ceramic;
3. Pulse;
4. Rechargeable.

DIY soldering iron: simple assembly diagrams

Before making a soldering iron with your own hands, you should determine what exactly it will be used for and what materials are available at home.

“Moment” from a house-saving lamp

Components of the device:

• Converter from an energy-saving lamp (power 40 W);
• Transformer;
• Copper wire;
• Frame.

The characteristics of the converter are suitable for a medium-power soldering iron. The safety of the device is enhanced by a standard fuse and overheating control on the thermistor. The circuit is very compact and can be placed in any housing.

The transformer is made independently. You can use a ferrite ring from a broken electrical transformer. The primary winding must be wound from 0.5 mm wire, the number of turns is 100-120. And the power one should be made of wire with a cross-section of 3 to 3.5 square meters. mm. You need to make one turn. We attach a tip made of nichrome or copper wire (1.5 - 2 mm) to it. The thickness of the last winding should be greater than the thickness of the tip. Next, you need to come up with a body for the device, make a switch, and the device is ready.

From a Chinese transformer

For manufacturing, you need either a working twelve-volt power supply, or one with a burnt-out secondary winding. Any Chinese device will do just fine.

It is necessary to remove the circuit from the case and check the serviceability of the parts. We do not touch the converter, since we only need to change the appearance of the transformer. Next, we remove the secondary winding and make a new one from copper wire (the cross-section should be 1.5-3 sq. mm). If the cross-section is small, fold the wire in half.

What is important is the overall cross section, which will be at least three squares. The winding is equal to one incomplete turn. Then, carefully thread it into the transformer body, first bending it like a hairpin. The transformer is soldered to the control board, and the power winding must be fixed with dielectric glue (for example, cold welding).

Next, we insert the circuit into the case.

A wooden handle from a regular soldering iron can be used as a handle. Other options are possible, given the compactness of the device as a whole. We insert a non-fixed switch into the handle.

The operation of a pulse device is based on a short circuit of the secondary winding , as a result of which prolonged heating can lead to destruction of the transformer and a fire. For this reason, a fixed starter is not permitted.

Next, you need to assemble the device completely and install the clamps for the tip (for example, inserts from a terminal box for wiring). This device is very compact and easy to use for small soldering jobs. Thanks to the replaceable tip, you can change its appearance.

These options are only a small fraction among the variety of schemes for manufacturing pulsed devices.

It is important to understand the principle of operation:

1. A device that converts electricity into high-frequency voltage;
2. Step-down transformer, designed only for high frequency;
3. The secondary winding, which forms a closed ring with a loop-shaped tip.

A pulse soldering iron is a reliable and economical device, and if you do it yourself, it’s also practically free. And in most cases, even a novice electrician can assemble a homemade instrument without having professional knowledge of working with radio equipment.

Source: https://tokar.guru/instrumenty/payalniki/impulsnyy-payalnik-svoimi-rukami-otlichiya-ot-obychnogo.html

DIY pulse soldering iron

Some models of pulse soldering irons may seem too expensive to the average user. Many people consider budget options to be of low quality, so sometimes people decide to make the instrument themselves.

It is quite possible to make a pulse soldering iron with your own hands if you have all the necessary tools and experience in such matters.

You should not expect that it will match the technical characteristics of purchased models, or surpass them in terms of convenience, but thanks to the relatively simple devices, the functional part can be copied.

Principle of operation

If someone plans to make an electronic soldering iron on their own, then the principle of its operation must coincide with the original product. The accuracy of the parameters is not very important here. The main thing is that the homemade pulse soldering iron works like a purchased one and also performs the same functions.

In standby mode, the basic principle of operation is based on the fact that the generator in the device microcircuit can operate intermittently. The microcircuit supplies pulses to the transformer. At the same time, the transformer itself supplies voltage to the capacitor and diode bridge. According to this scheme, it reaches the soldering iron tip, but the voltage is not yet sufficient to start heating to the desired temperature. It is only in a heated state in “standby mode”.

The circuit of a pulse soldering iron must contain a special switch, which creates the peculiarity of the device’s operation. When you press the button, the soldering iron goes into operating mode. Here, a capacitance of several capacitors is activated, which is summed up. Thanks to this, the generator begins to work to reduce the frequency until the moment when the transformer is completely saturated. After this, the power is pulsed into the tip, which instantly heats up.

Materials and tools for making a soldering iron with your own hands

Even for independent production, basic elements are required, which cannot be avoided during the preparation and actual creation of the product. The simplest pulse soldering iron can be made using the following components:

• Heat-resistant material for creating a tool handle;
• Copper wire, which will serve as a sting (it is advisable to sharpen one end into the desired shape);
• Transformer to create the required voltage;
• Copper bus.

Source: https://svarkaipayka.ru/oborudovanie/payalniki/impulsnyiy-payalnik-svoimi-rukami.html

Do-it-yourself pulse soldering iron: principles of operation, manufacturing diagram - Machine

A pulse soldering iron is widely used in working with power supplies of many electronic devices using soldering. The device is very useful and very easy to use. It acts as an excellent analogue to traditional options.

• How to choose such a soldering iron, how it differs from other models, and much more we will talk about below.

Soldering iron device

A soldering iron is a device that is used when working with various wiring diagrams and electrical circuits of various devices. The usual sting is used as a heating element.

Most often this part is made in copper. This metal is a good conductor and quickly reaches the required temperatures. The tip is heated by passing a small voltage current through it.

Pulse soldering irons are much more economical in this regard, compared to traditional ones. This is due to the operating principle of the latter. Voltage is supplied to the heating element only at the very moment of soldering, therefore there is no idling at all.

The first to meet the power is the converter, which operates at high frequency. It supplies the device with voltage with a frequency of 20 to 45 kilohertz.

Another, no less important detail is the step-down transformer, in front of which there is a simple microprocessor circuit that controls the circuits. Last but not least is the secondary winding that holds the tip.

Nichrome soldering irons

The types and design of pulse soldering irons have their differences. In the case of the device inside, they are insignificant. The models themselves differ more. There are quite a few types of soldering irons, which is due to the features of their design, operating principle and purpose. Let's look at the main ones.

Nichrome soldering irons have a spiral of the same name through which electricity passes. It can be constant, as from an electrical network, or variable, such as that which can be obtained from transformer installations.

More expensive models are equipped with a special temperature sensor, which can limit the device’s operating temperature, depending on the user’s preferences. This is done using a good old thermocouple.

The design of such soldering irons may vary slightly, depending on the manufacturer and price category. Cheaper modifications work with a nichrome spiral.

This option is not very economical, so more expensive modifications already use an insulator system to which a nichrome element is attached. This increases useful energy transfer and reduces energy losses. This design is similar to a ceramic tip, which is why buyers are often confused. We will talk about such models a little later.

More details about pulse soldering irons

Next come impulse soldering irons. Compact, productive, if you wish, you can figure out how to make a pulse soldering iron yourself. The reason for this is a very simple design, which we discussed a little above.

They only work when you press a button that you need to hold with your finger. Thanks to this, they have become so profitable in terms of energy consumption. The copper tip heats up quickly, and now, after 5-7 seconds, you can use the device.

By releasing the soldering iron button, it stops supplying power to the tip, which begins to rapidly cool down. Most soldering irons on our market are manufactured in Russia.

Their distinctive feature is the design, which involves connecting the copper tip to the general electrical circuit of the device, which already contains a transformer and converter. Due to the latter, the operating frequency increases, and the former equalizes the voltage inside the device during idle moments.

1. If you make a pulse soldering iron with your own hands, then you should know that its structure will be slightly different from that described above, in view of the fact that some components can be replaced with parts that are identical in functionality.

Ceramic soldering iron

Let's return to the topic of ceramic soldering irons. A ceramic rod is used as a heating element in such devices. This option is considered more modern and more reliable.

The temperature of such an element rises much faster, in addition, they are more durable in comparison with analogues made from metals and various alloys. Also, the ceramic tip is excellent for various temperature conditions and the accompanying power.

Gas soldering irons

Soldering irons that use gas in operation are devices independent of an alternating power source—autonomous. This is a huge plus of this option, but perhaps the only one.

• The tip can be made of different materials, but it is always heated by gas, which is burned inside the body and directed to the tip.

A simple canister is used as a gas source, which in some cases can be refilled. If you remove the nozzle with the tip, you can get a small gas burner. This may be useful to someone.

As you can see, the types and design of pulse soldering irons do not differ as much as soldering irons in general, but there is plenty to choose from. At a minimum, you can pay attention to models with a battery. They are well suited for small components, which are often found on the microprocessor circuits of small household appliances.

How to make a pulse soldering iron yourself

Now that you know enough about soldering irons, their types and operating features, you can think about making one yourself. The best option for such experiments would be a pulse modification of the soldering iron.

To do this, we will need all the parts necessary for the work. The first thing you will need to do is find a compact transformer. After that, you will need to buy, or use existing, LEDs - they will be our indicators.

We will also need a fairly thick copper wire, from which we will make a sting. You also need to get a button that will be used to temporarily turn on the soldering iron.

It is best to choose it together with a body that is made of plastic. The last thing we will need is a stand, which is made of dielectric material.

Now that we have figured out what a pulse soldering iron can be made from, we need to assemble the whole thing. For people who do not have special knowledge and experience in working with electronics, such a process will be an interesting experiment.

1. Inside, pulse soldering irons are a little more complicated than simple devices that work with heating elements.

We prepare our transformer. A switching type power supply is suitable for us, which can be pulled out of an old lamp in which light bulbs from 40 watts work. It needs a little improvement. After this, we place the part in the selected housing. The gun that everyone is familiar with is best suited for this. We install a button as a release lever.

Instead of the barrel we install a dielectric mount. It will hold our tip, which is connected to the secondary winding. The button will close the circuit and the tip will heat up. If you keep the button active for too long, the device may burn out.

Photos of pulse soldering irons

Read here: Choosing an anchor for concrete: types and correct installation Share with friends

Source: https://regionvtormet.ru/svarka/impulsnyj-payalnik-svoimi-rukami-printsipy-dejstviya-shema-izgotovleniya.html

Pulse soldering iron - differences from a regular one, features of operation and use at home

A pulse soldering iron is widely used in working with power supplies of many electronic devices using soldering. The device is very useful and very easy to use. It acts as an excellent analogue to traditional options.

How to choose such a soldering iron, how it differs from other models, and much more we will talk about below.

Two ways to make a pulse soldering gun

A soldering iron is one of the main tools used by electronics technicians in their work. In the process of repairing electronic circuits, the actual soldering takes relatively short periods of time.

In this case, the soldering iron remains turned on and radiates heat uselessly for a long time. In such cases, a simple pulse soldering iron that saves electricity can be very convenient.

Distinctive qualities

A pulse soldering iron has some differences from traditional devices used for soldering:

• operation in pulse mode, only when the button is pressed;
• quick warming up to operating temperature, the time of which does not exceed a few seconds;
• The tip of a pulse soldering iron is a conductor heated by the current flowing through it.

A conventional electric soldering iron is a device with significant inertia. Its tip is made of copper rod. Heating is carried out by contact method, by heat transfer from a nichrome spiral heated by electric current.

Heating of such a device can last several minutes, which naturally causes inconvenience. For this reason, such soldering irons are not turned off.

Pulse soldering irons are made in the form of pistols with a power button located in the trigger area. At the end of the “barrel” there is a loop of copper wire, which plays the role of a pulse soldering iron tip.

For the convenience of soldering, a backlight is usually located near the tip, which turns on when the power button is pressed. The role of backlight in older models of pulsed soldering irons was played by a low-voltage incandescent light bulb; modern models use LEDs.

Two types of power supplies

Inside the case there is a device power supply that provides filament current and backlight power. There are two types of power supply designs.

The first type is a transformer soldering iron. The design of such a block is very simple. Inside its case there is a conventional step-down transformer, designed to operate from a 220 volt network.

The transformer has two secondary windings. One of them powers the backlight lamp or LED. The second is a power one; the tip's filament current flows through it. The power winding contains 1-2 turns made of a copper busbar or thick wire. At the end of the “barrel” of the gun, this winding is securely connected to a wire loop that serves as a soldering iron tip.

The gun trigger makes a pulse connection of the primary winding of the transformer to the network. In this case, the secondary power winding, operating in short circuit mode, quickly heats up the working part.

The second type of pulse soldering devices contains a high-frequency converter. This scheme is certainly more complicated than the previous one, but due to the use of a high-frequency transformer, it can significantly reduce the weight and dimensions of the product.

Manufacturing according to a transformer circuit

As noted above, the electrical circuit of the transformer device is very simple. The main tasks that need to be solved when making a pulse soldering iron from a transformer are to find a suitable transformer, a pistol grip with a button, and put it all together.

As for the transformer, any power of 50-100 watts will do. If you don’t have anything like that at hand, you can purchase or remove from an old lamp a transformer, which is used in Chinese chandeliers to power 12-volt halogen lamps.

The secondary winding must be carefully removed without damaging the primary. Instead, one turn is wound with a tire of sufficient cross-section. Here it is important to select a conductor that will pass through the window of the transformer magnetic circuit. The tire must reach the end of the “trunk”, where it must be connected to a copper loop - a sting.

The transformer can be located either in the handle or on the “barrel” line. If possible, the transformer should be located as close to the tip as possible, since a significant current will flow through the secondary winding, and it is better to make this turn short.

Circuit with high frequency converter

To make a homemade pulse soldering iron of the second type, you need to assemble a frequency converter circuit. This task presents a certain complexity, requires some qualifications, and most likely the game would not be worth the candle if not for one circumstance.

A suitable ready-made converter is available in the electronic ballast, which can be extracted from an energy-saving lamp or fluorescent lamp.

Reworking the internal circuitry of the electronic ballast is minimal. It is necessary to short-circuit the conductors that power the gas-discharge lamp. After this, all that remains is to supplement the pulse transformer of the device with a secondary winding of one turn of thick wire. It's simple, but not quite.

This cannot be done on a standard transformer, which is equipped with electronic ballasts for fluorescent lamps. The fact is that this transformer is very small, and no wire can be inserted inside its ring.

There is only one way out. You need to find a larger ferrite ring and wind the primary winding around it, not forgetting to lay varnished cloth insulation between the layers. Through the hole remaining in the middle of the ring you need to pass one turn of wire, which will serve as a secondary winding.

The layout principle is the same as in the previous design. The transformer (and therefore the entire converter board) should be located as close as possible to the wire tip. The button, as in the previous case, must turn on the supply of mains voltage, in this circuit - to the converter board.

Advantages and disadvantages

A few words about the advantages and disadvantages of these designs. So, we have the following positive qualities:

• The pulse soldering iron gun is comfortable to hold in your hand, the power button is located under the index finger;
• quick heating of the soldering iron allows you to keep it turned off, turning it on only when necessary, which saves energy;
• The available backlight creates additional convenience when soldering.

There are some disadvantages that appear in the operation of pulse devices. One of them is associated with the intense operating conditions of the tips of such soldering irons. The fact is that the heating rate depends on the cross-sectional area of ​​the tip loop.

If you take a wire with a large cross-section, the heating time, and the amount of current required, increases. Thinner wire heats up faster, but also burns faster.

Unlike a conventional soldering iron, the tip of a pulsed device lasts much less. For this reason, designs should allow for easy replacement of this element.

Source: https://svaring.com/soldering/instrumenty/samodelnyj-impulsnyj-pajalnik

Pulse soldering iron from an electronic transformer: technology

Pulse soldering irons are a convenient tool for radio installers. They are economical and safe, although some models are quite expensive. In this case, people are looking for budget options.

The simplest thing is to make your own pulse soldering iron from an electronic transformer.

It operates in pulse mode only when a button is pressed, heats up very quickly, and also has a special tip, which is a conductor that heats up through the current flowing through it.

Which transformers are suitable for conversion

To make a pulse soldering iron, any transformer with a power of at least 50 watts is suitable. If this is not the case, try a transformer from an old lamp. These are used in Chinese chandeliers. You can save a lot of money on a pulse soldering iron, because the quality of its work depends on just a few factors. The price of the transformer is not included here.

More experienced craftsmen make a soldering iron from an electronic transformer. These are often found in Chinese lamps. For a trained person, such work will not be difficult. Here there is an W-shaped core on which the winding is conveniently wound. It happens that before starting work it needs additional soldering. The winding for a soldering iron is suitable from just one turn.

Step-down transformer

When it is decided to make a soldering iron from a step-down transformer, its power should be in the range of 50-150 watts. A smaller one will lead to overheating and the device will quickly fail; a higher one will make the device heavier. Among the advantages of using a step-down transformer are:

• The finished device will have low energy consumption. It will be consumed only at the time of soldering, and not during heating.
• Ease of use and maintenance. The tip is replaced quite quickly. For experienced craftsmen, this takes less than a minute.
• Safe to use. The sting cools down quickly, so it cannot get burned and set the table on fire.

Disadvantages include too much weight and size. The load on the hand is quite large, and with prolonged use it becomes very tired.

Electronic

The transformer is quite useful for working with many electrical appliances. The transformer power required to make a soldering iron is required to be in the range of 60-200 watts. Such a soldering iron will have the following advantages:

• The tip heats up very quickly, therefore, it is possible to carry out installation work in a limited time.
• The disadvantage of such a device is the difficulty with hard work of the stings. The appearance and large dimensions can also disappoint.

Materials and tools required to assemble a soldering iron

To assemble a soldering iron yourself, a seemingly quite simple device, you need to have quite a lot of tools.

It is equally important to use them correctly and know about the basic techniques that cannot be dispensed with during the preparation and creation of the product.

First of all, you will need: copper wire (it acts as a tip, so one end is sharpened to the required shape), copper busbars, a transformer and heat-resistant material. The latter will be needed for the handle.

Scheme and process of converting a step-down transformer

If you use a step-down transformer to make a device with your own hands, the first thing you should pay attention to is its power. It is required in the range from 50 to 150 watts. Even small deviations from the norm will lead to irreparable consequences. The primary winding does not need to be altered, but the secondary winding should be removed. This can be done by disassembling the plates.

It is important to make the maximum cross-section of the wire in the secondary winding. In this case, you don’t need to calculate anything exactly. The average value of turns is two. The permissible cross-section ranges from 6 to 10 mm square.

It is worth paying special attention to the turns of the secondary winding. Under no circumstances should they touch each other or the transformer core. In the case when the secondary winding is made of a copper busbar, its ends are used as current conductors. For this purpose, it is better not to cut them, but to fix the sting in close proximity. This is done to reduce the number of connections.

Thus, the reliability of operation and temperature conditions of the device will improve. At the end of the work, it is important to check the winding with a special tester.

Electronic transformer conversion technology

Source: https://OTransformatore.ru/svoimi-rukami/impulsnyj-payalnik-iz-elektronnogo-transformatora/

DIY pulse soldering iron gun from the USSR | Geek

You can easily assemble a pulse soldering iron yourself. The beauty of the proposed design is reliability, simplicity and at the same time decent power. Assembling such a pulse soldering iron with your own hands will not be difficult, but you can use it almost forever.

Recently, an electrician I knew proudly demonstrated a pulse soldering iron, which he had assembled back in the 80s of the last century and works perfectly to this day. A minimum of parts, the design of the soldering iron is simple and logical. It easily solders even wires with a cross-section of several mm.

How to make a pulse soldering iron

Of course, you can do everything “by eye”. But, by luck, a complete description of this design was found in one of the books. I think it's better to show it right away:

To assemble a soldering iron with your own hands, first of all, you will need to get a network step-down transformer. It is advisable to use a transformer assembled from W-shaped iron. The power should be around 40-50 watts. Flea markets are full of such goodness.

The transformer must be disassembled and all windings except the primary winding must be wound. It was already designed at the factory for the hardware of this trance and it is better not to touch it. But with the secondary winding you will have to get a little confused. But not much.

How many turns are in the secondary winding?

The secondary winding should have a voltage of about 0.8 Volts. But the number of turns in the primary may not be known.

To determine how many turns are needed, we first determine what voltage each individual turn produces. To do this, we wind 10-20 turns with any available wire. We measure the voltage and divide it by the number of turns. Most likely, only 5-6 turns will be required.

What to wind the secondary from

The current in the secondary winding will be tens of amperes, so it must have a sufficient cross-section. It is recommended to use a strip of copper foil 0.3 mm thick and 25 mm wide. It’s not so easy to find, and it also needs to be isolated somehow.

It is easier to find and use thick enameled wires. The main thing is that the total cross-sectional area is greater than or equal to 7.5 mm2 .

A wire with a diameter of 1mm has an area of ​​0.785mm2 . Accordingly, you will need to wind nine wires in parallel. When using a wire with a diameter of 1.5 mm, in principle, four wires in parallel are enough. It is better if the area is larger, so you can use more wires.

Current bars and tip

The ends of the secondary winding must be attached to copper bars with a cross-section of 8x3 mm. I don’t know where you can get ready-made copper bars. It is much easier to find and flatten the copper tube. Such tubes, for example, were used in the cooling system of old refrigerators.

The tip of the soldering iron is made of a strip of copper, 1-1.5 mm wide, or of copper wire. The dimensions of the tip are selected experimentally. You should not ensure that the tip heats up instantly. The heating time before melting the tin should be 1-5 seconds.

Button and light bulb

The general diagram of a soldering iron with a button and a paw is shown in the following figure.

To turn on the soldering iron, use the normally open button B1 . It is installed in the gap between the power cable and the primary winding of transformer Tr1 . When choosing a button, it is worth considering that when the soldering iron heats up, the currents through the button can reach 0.3A.

In order to see that the soldering iron is working, lamp L1 . Having a light bulb is very important. It is an excellent indicator of the operation of the soldering iron and can serve as a backlight for the soldering area. To power it, you need to wind another winding on the transformer to match the supply voltage of the light bulb.

Conclusion

If you make an impulse hoop with your own hands, according to the above design, then it is very important to well insulate the studs and nuts that tighten the core and copper busbars. To do this, it is better to use Teflon, varnished fabric, fiberglass or getinax.

Such a soldering iron, if properly manufactured, can be used for soldering with both fusible and hard solders. Well, you can use it to burn wood. It is advisable to select the tip so that the temperature in the solder drop is kept around 300-350 degrees.

The material was prepared exclusively for the website AudioGeek.ru

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Source: https://audiogeek.ru/impulsniy-payalnik-svoimi-rukami/