The build is topped off by a custom mahogany enclosure that is quite a bit overdone. A 3d printed trigger and welder handle wrap up the hardware nicely. While admits that a 555 timer or even just a manual switch and relay could have done the job, he opted for an Arduino Uno with a 4 character 7 segment LED display that shows the welding time in milliseconds. One of the most critical parts of spot welding batteries is timing. The tab can then be soldered to or spot welded to another cell. The operation is done and over in less than a second, well before any heat damage can be done. These dimples are where high amperage electricity quickly heats the battery terminal and the tab until they’re red hot, welding them together. You’ll notice that all battery packs with cylindrical cells have a tab with two small dimples. Spot Welding leaves two familiar divots in the attached tab, which can be soldered or welded as need.įor the unfamiliar, a battery spot welder is the magical device that attaches tabs to rechargeable batteries. And so it was that he decided to Build a Spot Welder from an old Microwave Oven and way too much mahogany, which you can view below the break. Of course, buying one is too simple for a hacker like. But when needed to build a battery pack out of about 120 Lithium Ion cells, he knew that he had to do it The Right Way and use a battery spot welder. Sometimes we get away with it when we have a small pack and don’t care about longevity. Raise you’re hand if you’ve ever soldered directly to a battery even though you know better. Safe is always a relative term when dealing with high powered devices, so be careful if you do attempt this build!ĭIY spot welders have graced these digital pages many times, including this one built with safety in mind, and this other one that was decidedly not. The level of detail makes this seem like a good starting place if you’re hoping to hop into the world of DIY spot welders. has detailed every step of building the welder, including changes to the off-the-shelf relay board and adding a potentiometer to the step-up converter board. They sit atop on a perfboard with metallicized holes to carry the high current. The capacitor bank uses nineteen Nichicon UBY 7500uF/35V capacitors, all wired in parallel using solder wick saturated with solder. ![]() ![]() ’s spot welder is designed to be just powerful enough to weld nickel tabs onto a cell without any overkill. Many projects work great with just a single Li-ion cell, but when you need more power, you’ve got to start connecting more cells together into a battery. designed his capacitive discharge spot welder to be safe, easy to build, and forego the microcontroller. DIY spot welders often use high-powered components that can be a bit frightening, given the potential for dangerous malfunctions.
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