Jeffrey Henderson | DIY Miniature Wire Spot Welder | Precision Wire Frame Modelling System | Part 3

Hi Everyone,
Welcome back to my UA-cam channel. It’s been a little over 2 months since I uploaded my last video. Mainly because of the terrible weather conditions, I decided to temporary halt any upcoming videos to my channel.
Until the weather becomes a little more reliable, I have decided to continue with an interesting project that I started last year. That project is the DIY Miniature Wire Frame Crimping and Merging Spot Welder System. So, during part 1, I demonstrated the modification of two transformers, and the design and build of all the systems controls. After that, part 2 came in late October, where I demonstrated a smart mechanism that now forms the handheld device of the stainless wire frame welder. The links are at the end of the description for those parts of the project.
So just to clarify, this project was initially started to assist another project/model (Wire frame model). The link is also in the description for that project too. I started this project in June of last year. Sadly, that project was put on hold until this one is complete as its required for it.
In this video Part 3, I finished the smart handheld device for the system. I begin by carrying out multiple sketches/initial ideas, progressing to design and fabricate additional parts, adding to the stainless/copper device (capsule of part 2). Note: The handheld device needs to be small but effective for welds to be successful.
This specially devised handheld mechanism directly connects to both transformer’s secondary windings, where a controlled high current pulse passes through the work piece to create a minute weld pool. In the video, I demonstrate the device crimping and transferring the high current in the correct direction across the shortest path of the test pieces. *(@ time 01.31hr)*
I mentioned in part 2 that structural weld is not important here, but a weld that is hidden and is barely penetrating the surface is more desirable as the work piece/model will be for visual viewing. The results ended up being mind-blowing, the opposite as the welds were significantly stronger than expected, tested/demonstrated in the video by hanging heavy 10kg weights on the test pieces.
The handheld mechanism keeps the systems electrodes isolated, which keeps the transformer’s secondary winding open until the weld process begins. This smart device also allows the copper bar/electrode to move in and out freely in a secure capsule along one axis. The bar is not prone to drift up or down, or side to side with a very low tolerance for error. The high temperature fibreglass insulators inside the main body acts as an insulating barrier, but also a bush, where the copper bar glides in and out.
The developed metallic guide containing the positive electrode is the main body (negative body) of the handheld device. The negative electrode attaches directly at the stainless-steel body, where the positive electrode slides freely in and out from the RCF enclosed capsule body. Once a weld position is selected, the electrode is release and the spring pulls the positive terminal out closing the gap between the electrodes.
A preloaded tension spring creates the desired clamp force. The device is created in a way that this spring can be interchanged to suit the bar diameters being used for the model/wire frame of their choice. The electrodes can also be altered, shaped, or interchanged to suit the task at hand.
The idea is to keep the current path as short as possible at the point where the high current cables connect, but also the path from the transformers to the handheld clamp must be carefully considered.
In the future during video part 4, I will complete the system by building the enclosure to contain all the circuitry and the modified transformers.
I hope you enjoyed this video, please hit the thumbs up if you did. It’s a project I’ve been meaning to cover the past 6 months. If you want to see this project evolve, please subscribe, and hit the post notifications bell to see the latest from my channel.
Please see video part 1 and 2 of this DIY miniature wire spot welder/precision wire frame modelling system below;
Part 1 focused on the combining of the modified transformers, controls, and the system’s circuitry.
• Jeffrey Henderson | DI...
Part 2 focused on the smart mechanism that forms the special clamp seen here that allows me to edge inside the 30mm rings to weld them to the outer bars/frames.
• Jeffrey Henderson | DI...
Also, please see video part 1 of the model (the reason) that I’ve built this smart wire welder.
• Jeffrey Henderson | 1s...
Also, please see my pneumatic handheld spot welder system that is much more sophisticated than this one.
• Jeffrey Henderson | Ho...
Peace out and much love!
Jeffrey 😊
#3dprinting #creative #innovation #engineering #engineeringstudent #uniqueart #UniqueGifts #uniquedesign #unique #RealTalent #jealousmuch #threatened #envious

[@MaxGalloway-pq1qx]

Hi Jeffery, I came across your channel looking up welders. Your craftmanship is on another level. Great knowledge and serious attention to detail. It's clear you take great pride on your projects. Get your hands insured! You have got a new subscriber 😊

[@JeffreyMaster]

Hi, thank you 😮
This has been the fastest growing video on my channel for some strange reason. The others are limited, which I will never understand as they are much more diverse/complex and different. I will keep them coming, but hopefully, quicker 😊