Power Spot Welding Machine for Lithium Battery Simple Homemade

 

Power Spot Welding Machine for Lithium Battery Simple Homemade

     Here’s how to build a simple power spot welding machine for lithium battery using the components you've specified:

    Components:

     1. Relay: 24V (rated for high current, e.g., 100A).

     2. Transformer: 220V to 24V output (to power the relay).

     3. Power Source: 12V battery (18–60Ah, capable of delivering high current).

      4. Push Button: For manual control of the welding pulse.

      5. Resistors: 1k and 2.2R/2W (to limit current and manage spikes).

      6. Capacitor: 6800uF/35V (to stabilize spot weld).

      7. Additional Components: Copper electrodes, thick wires, connectors, insulation

       materials.

     Circuit Design:

   1. Transformer and Relay Coil:

            >Wire the 24V transformer with the 230V AC. 24V out drives the coil of the relay.

            >Connect the relay's coil in series with the 2.2R/2W resistor to limit the current. This gives the relay the time to activate without burning up.

   2. Push Button:

            Connect a momentary push button switch in series in the relay coil circuit. It gives you the ability to turn the relay on and off when you want.      

 

   3. Capacitor:

            Connect the 6800uf capacitor between the relay coil com terminals. This stabilizes the voltage so it does not surge and cause arcing when the relay is cycled.

  Welding Circuit:

          1. Now you have the 12V battery's positive connected to the relay common.

          2. Thick wires are used to connect one of the copper welding electrodes to the relay's normally open (NO) terminal.

          3. The second electrode connects directly to the battery’s negative terminal.

  Electrodes:

        Replace welding electrodes with copper rods or heavy wires Prevents overheating by ensuring appropriate insulation and grip for accurate welding.

***Circuit Diagram***

   Operation Steps:

      Setup:

            Keep your welding electrodes on the nickel strip of the lithium battery where you want to weld.

            Enable the relay coil by connecting the transformer to the 230V source.

   Welding:

            Momentarily depress the push button to activate the relay and pass a high current from the 12V battery through the electrode.

        A short pulse (usually a fraction of a second followed by releasing the button) completes the weld.

  Safety Tips:

       * Make sure all wires can handle the high current output of the 12V battery.

       * Be sure to insulate every connection to avoid short circuits, or getting shocked.

       * Run small tasks on the machine before using it on full scale to check stability.

     This configuration works great for welding nickel tabs to lithium batteries. Very simple, cost-effective, and a good way to build your own packs. If you want a schematic or more info just let me know!