BOSS LEVEL CUSTOM SPOT WELDER

Batteries, Chargers, and Battery Management Systems.
hemo   100 W

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by hemo » Jun 03 2019 3:59am

derekisastro wrote:
Feb 28 2019 8:10pm
Seems like I have run into the same issue as Hemo.

I will need to take apart the spot welder and check my Arduino board ... if it is indeed the same problem, I may end up replacing the board myself and getting the files from Aulakiria.

I'll be back if it is another problem ...
My new upper Arduino board didn't resolve my issue so rather then pour more money in to it, have all but given up with it now. Cost or repairing /sending to and fro makes it not viable for me.

Currently using a Malectrics which is as equally as good if not actually better.

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 03 2019 4:45am

I did this weekend a shockproof pack for a Trampa mountainboard. My customer is more of an animal than a human so it really needs to be rock solid to last in his hands.
I used both welding and the neodinium magnets technique. The welds are really really unlikely to fail due to vibrations and continuous hard landings.
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The neodinium magnets technique has been widely discussed at this very forum. Once the magnets are epoxied/glued or stuck somehow they do not let the copper sheet move. I used 0.1 copper sheet and my boss welder.
I used a smart bms to charge to 4.10v the cells, skip voltmeter and lock the battery. Controlled by Xiaoxiang app android.
It has high density foam on and under the pack so it can absorb vibrations. Of course insulated with kapton, barley paper and eva foam. The spacers grant both natural cooling and increase greatly the structure strength. Has some glass fibre tape too.
It's been put inside a carbon fibre box and has a fuse protection.
There's no way to destroy this pack ;)

I taped part of the proccess. I will make a video if i find some time.

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 06 2019 2:46pm

I have tested the sandwich method with the boss welder today.


0.1 sandwich test.jpg
Left is sandwich method and right is direct spot weld.
I guess that method is good for machines unable to weld copper but not for the boss welder.
Direct is far superior with this machine.

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spinningmagnets   100 GW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by spinningmagnets » Jun 06 2019 5:44pm

What thickness of copper sheet are you using? What size and N-rating of magnet are you using? (link?)

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Matador   10 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by Matador » Jun 06 2019 6:39pm

:shock: :o :twisted: Awesome !

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Matador   10 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by Matador » Jun 06 2019 6:40pm

You did it for real ! 0.1 mm pure copper:


Where a 0.1 mm x 10 mm strip of Nickel could safely pass 4.1 amps
Where a 0.1 mm x 10 mm strip of Aluminium could safely pass 9.6 amps,
Then a 0.1 mm x 10 mm strip of Copper can safely pass 15 amps,

So imaging when you weld copper sheet instead of copper strips !!!
Pretty sure you can safely pass 90 amps through them... and this is a rather conservative ampacity rating (extrapolated from powerstream.com)...

My only concern is: are 0.1 copper sheath strong enough not to sheer off un stress and vibrations ?

I used 0.127 mm copper sheets to do a pack (god forbid, I soldered it), but it's holding off real well.

Pics of mine:
https://endless-sphere.com/forums/viewt ... r#p1414963

Matador

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 07 2019 12:49am

spinningmagnets wrote:
Jun 06 2019 5:44pm
What thickness of copper sheet are you using? What size and N-rating of magnet are you using? (link?)
That pack has 0.1 pure copper. The magnets are these:
https://s.click.aliexpress.com/e/bXeMJ9ZO

The pack has been tested under rough conditions. Very intense vibrations and shocks. So far so good.
The same guy destroyed his previous commercial pack in under a week. I am confident on my pack. Weld+magnets will not fail easily

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 07 2019 12:54am

Matador wrote:
Jun 06 2019 6:40pm

My only concern is: are 0.1 copper sheath strong enough not to sheer off un stress and vibrations ?

I used 0.127 mm copper sheets to do a pack (god forbid, I soldered it), but it's holding off real well.

Pics of mine:
https://endless-sphere.com/forums/viewt ... r#p1414963

Matador
Well ...that is my main and only bike right now. It has dual suspension so vibrations are not so hard. The pack works like a dream. Has a monstrous power. So far so good. No issues at all

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 08 2019 11:26am

I just did another pack. Same method, 0.1 copper sheet+neodinium 12s4p with sony konions vtc4+120amps bms inside a waterproof pelican case. 3.2 kg of pure powah for a trampa e-mtb
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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 14 2019 2:12pm

Today i made another sandwich method test with the custom boss spot welder.
I am very happy with the results. Copper on copper sucks. I have never managed to make a decent weld. They do not stick. Using the sandwich method i made two strips of copper with nickel inside stick and two strips of nickel with copper inside stick too.
Even though i prefer wide tabs this could be useful. Making it possible made my day.
all.jpg
left= double sandwich---------------------------------------middle single sandwich---------------------------right= copper on copper
copper on copper.jpg
copper on copper=very weak welds. NOT viable
single sandwich.jpg
single sandwich= copper on copper with some nickel inside. Successful
double sandwich.jpg
double sandwich=copper+nickel+copper+nickel. It failed yet seems two nickel strips with some copper inside is viable

These tests could be useful. The sandwich method can have some applications after all with this machine.

This is the video:


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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 17 2019 5:08am

Good morning. For those who have difficulties with the pen maintenance and building new ones you will be glad to know that the sunkko is discounted now.

https://s.click.aliexpress.com/e/cmVje588

Just solder an xt90 and ready to go.
The tips are extremely expensive but I think you should be able to make your own with this:


https://s.click.aliexpress.com/e/9lO9hFa

Hummina Shadeeba   10 MW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by Hummina Shadeeba » Jun 20 2019 11:54am

Is the speed the welder can work limited only by heat? Can I weld repeatedly in succession if staying under the 40c?

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jun 20 2019 12:46pm

Mostly yes. Fets will die eventually but heat is what will kill them fast. If you keep the machine cold you are good for next weld.

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Jul 28 2019 5:50am



I did this video for another forum yet it's interesting here too. Order matters:


1st I tested copper on steel and nickel on it.
Good results as usual

2nd I did copper on nickel. Not very good yet acceptable.

3rd nickel on copper. Very good.

As you can see the order matters. Copper on nickel makes weaker welds using the same settings (9ms X2)
Copper on copper sux. I said it several times. Not viable not even using tungsten points. At least I didn't succeed so far.
Make sure the strips are flat and you make good pressure or you will make holes. Copper needs a lot of practice to master. It's as easy as nickel once you figure it out.

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by elhnad » Dec 05 2019 3:04pm

rojitor wrote:
Jun 07 2019 12:54am
Well ...that is my main and only bike right now. It has dual suspension so vibrations are not so hard. The pack works like a dream. Has a monstrous power. So far so good. No issues at all
[/quote]

is the minispot a capable of doing .1mm copper foil? i know you wrote .05mm was doable but I am also concerned it's too thin and will tear.

also, why do you use the magnets if the copper foil is already welded. i thought the magnets were for solderless / weldless packs?

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Dec 06 2019 4:04am

0.1 totally not recommended with the minispotA.
The heat is xtreme.
0.05 is a very good choice. I did packs with it. Better than 0.2 nickel imho.
The packs with magnets are shockproof. For trampa mountainboards. The magnets are a plus in reliability. Jump high problem free.

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Okami   10 W

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by Okami » Jan 08 2020 2:32pm

Ok, long story short - I thought my welder went dead when actually it was wire coming loose off the Lipo cell Tab.

Due to difficulty soldering the wire back to lipo (because of going from 4s to 3s lipo), the new solder connection didnt stick very well and started coming off.

I did think for a few moments I killed the mosfets, when in turn lipo didnt give the power, as the welds were super weak before hand also.

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by cheapcookie » Jan 30 2020 5:18pm

Hey do you guys have a spot welder to recommend? minia ? s2? kweld? alixpress?

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by amberwolf » Jan 30 2020 5:34pm

recommendations depend on specific usage scenarios. ;)

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izeman   100 GW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by izeman » Feb 19 2020 3:01pm

Thanks to forum user Maddin88 who owns a kweld which is able to show current draw from the battery, I was able to check my 4s A123 AMP20 pack's capability. This pack was built from 6y+ old b-grade cells which set on the shelf for that time. I put them to new use, combining them with metal clamps. Soldered #10 battery wires to it, but those may we replaced for #8.

Welding showed a max current of 1200A+. Quite nice :)

I also ordered an electrode set from aliexpress for $10 and replaced the wires by #6 silicone wire.

Comparing this welder directly to a kweld, i must say that the kweld looks more user friendly and more feature rich. Also it handles thicker nickel much better than this one. On the other hand it may be that i puts way too more energy into the weld.
Eg. Setting to 40J for a 0.2mm weld showed 30ms welding time (with 1200A that is)
Setting it to 30J gave 17ms (similar to max setting of my welder) but results of the kweld where still way better.

This is what the setup (with a big heatsink installed) looks like now:

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by izeman » Feb 20 2020 5:34am

This is the electrode holder I bought (together with 2x 50cm of #6 silicone wire)
https://www.aliexpress.com/item/4000544 ... 4c4d354x2d


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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Feb 20 2020 6:21am

Looks good. Nice find.

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izeman   100 GW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by izeman » Feb 20 2020 8:35am

rojitor wrote:
Feb 20 2020 6:21am
Looks good. Nice find.
Thanks. I always take your videos as reference to see if a weld it ok, good, or perfect. I use blades for testing as well, but have a strange phenonem. It seems that turning UP the time makes welds not better, or at least I don't see those massive burnings as in your video.
I can make welds that stick fine most of the time, and sometimes 5ms is better than 7ms or even 10ms. Welds where little dots stick to the battery and leave little holes once you rip off the strip. But the kweld just makes BIGGER dots. Any idea why?
And I found it needs 3x for welding a strip over another one, already welded to the cell. Can you confirm that? If I do it with the same settings (1x) as for normals welds it will just fall off.

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rojitor   100 kW

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by rojitor » Feb 20 2020 11:45am

When you weld on top of other layers sometimes you have to rise power a little but all that depends on the lipo you are using. I can't tell the difference with kweld because I do not own it. Won't speak about something I don't know about.

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Re: BOSS LEVEL CUSTOM SPOT WELDER

Post by Gizmosis350k » Jun 07 2020 1:21pm

I have a typical very oversized dual transformer (one 40/100a one 12v circuit feed) spot welder, ....what else do it need to be brazenly welding copper tabs to my battery????

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