Battery Tab Spot Welder - Extras 1 - Electrode Assembly

[@gtag174]

Well that's a decent idea to have the electrodes clamped. Overall good job Jim. I've been designing my own and so far just got the pcb done and searching all over the internet on how the professional ones with air pressure use the electrode to lower and raise the electrodes. I was thinking for RC servos.

[@ThingsWhichArentWork]

Hi George - I planned out all sorts of clever ideas using spring-loaded electrodes to accomodate any offset in the electrode lengths, and then having an adjustable spring mechanism on the trigger switch so that I could set consistent pressure - however, having tried this one out on a simple pack, I don't feel the need to go further along that route - The current welder is good enough for me to make two or three battery packs a year. Have you thought about using a solenoid for raising the arm, and just counterweights to drop it back down? The counterweights would give you a nice constant pressure and you could adjust the weights easily by adding/removing weights from the ends of the arms. Cheers!!

[@gtag174]

Jim Conner thanks for the idea. But a solenoid would be too harsh on the cells while coming down or while raising them and controlling them would need additional circuitry. I've managed to use a servo and control the speed to lower and raise a pair of electrodes. Now waiting for a few stuffs to arrive to assemble the parts.

[@esqueue]

Awesome, I'll use this to design that arm in plastic. I am using PETG so it should be able to handle the heat. If not, I'll try wood. Thanks for the video and all the time spent on this project.

[@ThingsWhichArentWork]

If you want me to share the fusion360 design so that you can edit it, make changes etc, then I'm more than happy to do so. I tried to make the design public already, but I believe that fusion360 lets people collaborate on a design - If you give me your fusion360 username then I'd be more than happy to add you to the project. It would be great if the whole design could be 3d-printable. Cheers!!

[@esqueue]

That was a quick response. I was using your aluminum clips to design one but realized that I forgot to make the end that clamps onto the front smaller so that they can fit into the clip. Yeah, it would be awesome if you upload the plastic piece. I can easily edit it to my needs.

[@RWBHere]

I cringed when you used a pair of pliers for those nuts at the end! But then, when a spanner isn't available..... been there; done that! It's avery neat tool that you've constructed. Thanks Jim.

[@DansKoiPond]

Hi Jim what stops the two wires shorting through the aluminium arms?

[@ThingsWhichArentWork]

Hi Dan - There's a 1.2mm gap between the aluminium arms, maintained by the 3x spacer clips I printed off. Cheers!!

[@DansKoiPond]

Jim Conner ok that's cool I couldn't see that and it confused me. I have to say many on you tube have made spot welders before and its not worked well but yours seems to work really well.

[@meehan302]

Quick Nd smart Jim.

[@ThingsWhichArentWork]

Thanks Patrick - Hope you enjoy the rest of the series too. Cheers!!

[@BenjasUberHobby]

:)