How Welding Transformers Work. Teardown and Explanation
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- čas přidán 17. 07. 2024
- In this video an arc welding machine is analyzed.
My latest video about reverse engineering some of the welding machines:
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• Isolation Transformers...
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New video about welding machines is now online: czcams.com/video/6Gx9cBPrjAs/video.html
I made mine last year and the duty cycle seems to be all day long I used 5 MOT in series with 8awg wire with 8 turns on all the sec windings and it works like a charm although the voltage is a bit low 30v it actually welds like a champ in case you are wondering it outputs around 200amps
Hey Mr. Gerolf, are any future TV-appearances planned? I really enjoyed the few episodes they had with you on DMAX!
3:21 Is that the compressor you bought at the scrapyard?
I am NOT an electrician or something like that!! Watching this TUTORIAL makes me feel like I could become an electrician. WELL - THOUGH & PREPARED => WORK!! T-H-A-N-K-S 4 the AMOUNT of TIME spent on this! You should REALLY consider RE-UPLOADING this TUTORIAL in/auf DEUTSCH😅
very good command of english for a not native speaker, solid theoric knownledge of electronics, good video making skills, and bit of humor. you are the man, man! :-) Grusse aus Italien
I wish my professors in electrical engineering had been as articulate and concise as you. Thank you for taking the time to deconstruct these systems into their basic, first-principles components and concepts!
+OTL Productions I feel the same way, 2,5 year into my EE degree and I still learn alot from these videos! Also they are fun to watch :D
+OTL Productions I wish EXACTLY the same thing too! At least some of them were decent enough so by paying attention, all this stuff here makes sense, instead of trying to learn it now.
I enjoy watching your videos and experiments. Way over my head and too late to learn at 72 years old. I was a welder for 40 years and really enjoyed what I learned while welding. Now I have a couple of welding machines that I need to repair and was trying to see if I could gain any information on CZcams. It would have been nice to learn the electrical side of the machines I have used. Keep up the great work and teachings, much appreciated Sir. Paul Greenlee
Thank you. I think that I'm very fortunate to live in a time when I can watch teachers and researchers do their work like this. It is a very personal experience. Thank you again.
This literally answered every single question I had about the mechanisms by which transformers operate, in a remarkably well-structured format demonstrating a thorough understanding of the subject matter, making for the most time-efficient educational video I have ever seen in my life. Outstanding channel. I have never subscribed to anyone so fast before. This man is a veritable genius.
Though i am a doctor by proffession yet i have great love for electronics and respect for the geniuses who have shown what human mind is capable of. Your video has been a great help to further my understanding oc transformers. Thank you!!
I feel smart just watching this. So much information and explained in an accessible way!
The information density of your videos makes for one of the best channels I've seen
Nice stuff
I've been an electrician for over 30yrs. I was apprentice of the year for my class and I have to say THANK YOU. Its been way too long since I've studied electricity. I knew there was a good reason I subscribed.
Being an engineer n enthusiastic of "how stuff works", I have bee watching electrical n mechanical videos on you tube since 2012-
Today i stumbled upon best video i ever watched, which gave me great deal of knowledge n information. Must admit being good in academic n practical, i had overvalued myself. I m down on earth after watching n listening to sound technical knowledge from this video!
Thx not only for uploading it, but reveling me how practical n knowledgeable a person can be-
I just love the simplicity of the old welders! Our forefathers are a lot more clever than we give them credit for.
I could listen to TPAA all day. I love how he sounds so casually brilliant. He's like this regular guy that you went to high school with, who also just happens to be an actual mad scientist. It's awesome.
to the sound of evil buzzing at 50Hz:
"as you can see, we are at an output power of roughly - oh wait, my Fluke is melting"
great vid and perfect demonstration of shunting
For this application a current clamp would be very very very advisable . Btw , personaly i have great respect for classic welding machines , if you don;t abuse them they will last millenia . Perfect for post apocalyptic home use .
Love your work ! I have an Electronic Engineering degree from 30 years ago, but I find your exceptional clarity of explanations wonderful for clearing the cobwebs away from the long dis-used magnetic theory stored in my head from way back then :) Ive mainly been a "Digitologist" in my career, working with Microcontrollers, PowerFets and embedded systems (EFI, Robot ESC's etc) so to see you working in the power electronic/electrical realm is excellent !
...aaand. funnily enough, just a little while ago, I bought a modern DC Inverter Tig (and Plasma cutter) and taught myself to TIG weld (through youtube videos of course).. and I would *love to upgrade it to be able to do AC for Aluminium. Like you, I cant quite swallow the extra $600 (Australian) more than the DC machines just to do AC for some occasional Aluminium welding..
... so If you are planning on trying to come up with some form of add-on micro-controller board to be able to generate the wave-forms (Frequency, Mark/Space ratio (cleaning action), Pulse Rate, Ramp up and Down, and external control (pedal, finger pressure trigger) etc, required to make a DC welder into an AC one, then I'm with you 100%. Ive already joined your Patreon campaign, If theres else I might be able to help things along with, let me know....
...If you think its possible to microprocessor control the DC Welder electronics without requiring major PowerDrive component replacement, then maybe a Kickstarter project to develop an Open-source modulator add on board would garner some support to help development along ?..
..In any case, keep on with the videos, theyre great ! Thank you ! :)
SpockieTech Hey first of all: Thank you for your support! It's great to known that I have obviously found a topic here that is "right down your alley")
If I can find a reasonable way to convert the DC welder, then I indeed might think about a kickstarter campaign. The biggest problem with that will however be that there are so many different types and brands of machines that it will not be possible to create a module that will simply "fit" inside any given model. but we will see about that once I have done further research in that direction.
I could write a lengthy piece detailing the various ways you impress with your videos, but I'll say this simple sentence, with deep & profound meaning behind it:
You Sir, are an asset to a world of hungry minds...
Thank you!
From Joseph in Hudson Falls, New York, USA. 😎👍
Wow. So impressive.
I am quarter German and I am sure I had the same monotone voice when I explained things to people as well.
I am retired now but people commented about this to me when I worked and I realized I was doing it intuitively because it’s the most efficient way to teach someone. Being and acting like a clown or following like a sheep makes you popular but you don’t achieve anything.
They called me a genius so many times I was sick of hearing it.
I am sure he also has a very good sense of hummer as well.
I feel like giving this guy a job not money.
Sure it was not perfect and some depressed people will pick on the small cracks in his explanations but this kid presented a brilliant summary with virtually nothing.
Thank you so much for your efforts.
I love these experimental setups you used to do.
That reminds me.... I've got to get my dummy load designed. .. should keep me busy for a few days of lockdown.
As usual, I only understood about half of the info you presented but I sure learned a lot. Reminds me of the old adage about drinking from a fire hose. I keep going back to videos that I've already seen and learn more each time. Thanks!
Fascinating stuff. Its much easier to learn this stuff from such a concise format as these well done videos. Plus this generally isn't the kind of knowledge you run into outside of an electrical engineering degree by the sounds of it.
Thanks for your time, money and effort into this piece of work.
ASTONISHED BY THE QUALITY OF YOUR VIDEO :))) Best video I've seen on YT in the last years. I'm visiting your Patreon site now.
It would be terrific to have someone like you as a teacher at our school!
Great video.
Crisp and easy explanation, that electrical students can understand well. Good job....
Extremely good and clear output, as always! :)
Your videos are great, I enjoy listening to you speak. Very concise
What a brilliant video!
Clear, concise and no jibber-jabber.
I understand my Welder better because of this video.
Perhaps I can get it working!
Thank you very much!
I really liked this video, i just started my first electronics design job and now only design FPGA/analog stuff for the semiconductor test industry. now I finally got the money to do cool projects like this.
I have a feeling some of my tutorials helped you disassemble your transformer :). Well done, interesting video. I appreciate a thorough explanation that is not too technical. Great content.
Thanks for showing the dusting with the compressor, that was super satisfying.
That's the only thing you learn from this video , Lol - you're a genius man
So well explained!! I wish my university teachers would have been only a fraction as good as teachers as your videos!
you are a very good lecturer and your videos are priceless. God bless you
This is my favorite video by one of my favorite u tube channels . thank you
By far the best, most educational video on electrickary. Well Done
Loved your video! Always neat to learn new things about welding.
I know NOTHING about electronics, but still I watch these videos. I have almost no idea what you're talking about, but as long as you keep saying 'moss-fats' and I'll stay subscribed :)
Wonderful Video! I will donate when able. Thank you for the excellent videos!
Thanks for an excellent video. AC/DC welders are fascinating and as you know fall into two main groups, the older being switched by SCR pairs and the newer ones with IGBT units. Hope you eventually get to look at both kinds and share your thoughts. The dummy coil in the back of all the SCR units I have seen is fascinating and seems to be a balance coil to save the SCR from damage when the field reverses. Look forward to future videos.
I have one of those welders, and added a 110mm 220VAC fan on the rear panel to cool it, which helped a lot with increasing duty cycle from it's original 2 minutes per 15 minutes to around 5 minutes per 15 minutes. It keeps the core cool, even if the stray magnetic field when the arc strikes stops the fan dead while welding.
Awesome presenter. Zero fluff. Very smart
Great video. You have excellent teaching skills and a very professional voice.
23:50 thanks for showing this picture it helps me to understand the mystery of shunt plats :)
This is so great and so inspiring. Thanks for doing this.
I thoroughly enjoy your videos. Very educational. Keep them coming.
Very good video, as always very educational with explaining everything in details with examples. :)
nice explanations, and good discipline in creating this tutorial
Very informative. Im impressed. Well done!
Awesome video.. Definitely looking forward to the next ones!
Very cool. Your explanations were a great brush up on transformers. I found the part on stray field transformers and coupling to be quite informative as I haven't thought about those in some time. I finally found my first mot to fashion a resistance welder for both batteries and general spot welding. I plan to also build a basic arc welder with a variac, but would like to start working on a couple switching designs soon. Thanks for the video.
Well I am here again... The spot welder turned out nice, but I have an interview coming up and was trying to find some good review on the PWM control design for switching DC welding. Any good resources?
Fantastische Video! Große Lektion in Induktivität, Elektrotechnik und Transformatoren.
Love the way you explain things. I'm already a subscriber.
SOmehow I prefer your videos even more than those other super high budget youtubers
Extremely thorough. Well done.
Like the coverage of things we take for granted, transformers are more than step up, step down and isolation.
Excellent detail in practical and theoretical regards. Thanks for sharing!
Thank you so much for this video. I learned so much!
Fantastic and well explained video! I learned a lot.
Excellent Video as usual... Thanks for sharing
Brilliant. Good science and cleverness. Spend much time in a factory? Say as a Millwright or Electrician? I feel like I know you.
Writing in 2018, this style was really fun. There is value in that.
Excellent lesson, you are an outstanding teacher, remind me of Salman khan. You know how to explain things that seem difficult when explained by 99% of teachers and engineers.
I hope you make lots of videos experimenting with different electronic devices.
Thank you, keep it up
Great video! Hope to see the next one soon!
I wish i understood this better than i do, but great anyway. I enjoy your videos, and hope to learn from your also.
Well another superb video here... I wish I had such a good teacher in my earlier years... Can't wait to get more of these incredibly informative videos. Thank you for all your time and efforts at making these tricky subjects so clear and understandable by the masses ! If only I had s few dollar to spare, I'd be glad to help you build your TIG devices from spare parts... I'll try to play lottery...
DJSolitone Thank you :). Your "mental" support is just as important. If it wasn't for faithfull viewers like you guys out there, I would have stopped making videos a long time ago. Even if youtube was a goldmine...
Extraordinary video. Thanks!
very detailed and informational explanation, thank you
اقسم بالله اني احببتك واحببت قناتك .... عن جد انت ممتاز ...very very good ....thanks
Thank you. That's exactly what I needed to know.
I went to school for the wrong thing every time I listen to these videos I get excited to learn more. Should have been a engineer.
Great video, very nicely explained.
Wicked cool, u are my favorite mad scientist as of now🎆🎆🎆
Amazing video dude, regards from argentina.
thoroughly enjoyed your video, even speaking in your second language you are a better teacher than my professors lol
Thanks for the good explanation. Thank you very much
Your the champ! another excellent vid!
Cheers from Toronto
You have really great videos and you can think really well. Many hours of work must have gone into that. Thank you for the great material! I live near Hamburg and might need your help and advice with some projects I have in mind for the near future. Thank you!
I'm simply in awe of your brilliant effort, delivery and genius! Yours are the most productive, inventive and knowledge packed videos on the entire internet and my appreciation for your effort can only be expressed in e-notation! 6.022 x 10^23. Keep up the great work!
Hello! Great video as always! I'm figuring out a possibility to rectifier the output of stray field welding tranformer in order to achieve a better welding result. In my mind the output filter would be better implemente by an inductor. What do you think about that pissibility? Kind regards AT
"wow" so impressive ! I have to admit the majority of it seemed far beyond the scope of most CZcams viewers comprehension myself included - but it was such a technological coaster ride I was literally dumbfound with amazement anyway the whole 9 - it would take years for me to understand it all but I do have appreciation for brilliance when I see it - Thank You
From a far less convoluted point of view lol I will offer some potentially positive feedback that may help your ratings and hopefully enchant your financial success at least to some degree - that is to keep in mind makeup tutorials for example on this site get up to a million views in just 6 months - your videos are getting less then half that and my suggestion is to try and tone it down a bit - more specifically try and convey information to a much broader range of intellect - your communicating to us all to often as though we are AWS certified engineers or something of a similar caliber and most people of this nature find better things to do then look at You Tube videos in the first place - I've never welded in my life but I am very interested in it and have several home projects in mind for it - just not sure where to begin with getting a machine to start with
I noticed your Calif T shirt - I was born there :) and still live in So Cal a good part of the year - I am dual residency now and I own a home in the Midwest surrounded by farmland as well - Iv'e vacationed in Germany - Cologne and Munster were some of my favorite towns and I still own the 18 piece German made silverware set I purchased at Woolworths in Frankfort - Actually I just stumbled into your video while researching my options for a first welding machine - the more I read the worse it gets Lol - I am confused I don't know what to get !!! - it's not as easy to understand as a Silverware set
This is EXTREMELY well done, a brilliant exposition in near-flawless English and nicely touched with colloquial bits of humour too. Few of my British colleagues could come close to matching it.
The subject matter is not 'advanced' from the point of view of someone with a decent education in electrical engineering - these are fundamental concepts that you would be expected to study during an electrical apprenticeship or first-year degree material. It makes excellent revision or supplementary viewing for someone doing that. Iron cores, laminations, eddy currents, airgaps and magnetic flux are very, very familiar to anyone working in that field. But it's incredibly rare to hear it described so lucidly, a tour de force and very well done indeed.
And, having said that, I have a degree in electronic engineering yet I didn't know about inrush current in transformers caused by remanence, so I'm going to have to read up on it.
If you are familiar with the subject, that throwaway line about the unlikeliness of achieving magnetic saturation of air is priceless, an absolute gem. It's entirely clear that for the person who wrote this has an exceptional theoretical and practical understanding of the subject matter and the physics involved.
Great video on how it is broken down to the t.. Man I wonder how long it took u to set everthing up and how long it took u too learn all this .. I have too say u are one smart dude !! Keep up the good work and showing us how all this works !!
perfect explanations !
Great explanation. The genius man you are showing respect must be Charles Proteus Steinmentz.
I built my own arc welder by rewinding the secondaries on some microwave oven transformers. I even d/c weld with it through an MDQ200A bridge rectifier. It works.
I am NOT an electrician or something like that!! Watching this TUTORIAL makes me feel like I could become an electrician. WELL - THOUGH & PREPARED => WORK!! T-H-A-N-K-S 4 the AMOUNT of TIME spent on this! You should REALLY consider RE-UPLOADING this TUTORIAL in/auf DEUTSCH😅
wow my head is spinning Great depth!
Appreciate the efforts
Excelent video. Thank you
i hope you can make a lot of video in the future. thanks so much
Thanks for the vid, nice vise!
***** If you like it, I recommend watching my video about that vise:
czcams.com/video/6_Lf9S0wE5s/video.html
An even more beautiful one is restored in this video:
czcams.com/video/Z0Tgcgr_I20/video.html
You videos are fun and educative thanks alot 💕
vary nicely said Thankyou
Great explanation! The only thing missing was the equivalent magnetic circuit.
Damn I love you germans !! And all the wonderful tools that comes out of your country !!
ts off to you sir! Impressive!! :)
A tip for cleaning a really dirty electronic part is to use a pressure washer. After a few day it can be powered up again one it is completely dry. This applies to old television sets, old radios etc.
Du erklärst das besser als unser TECH Lehrer :D Bin jetzt E2 und auf nem Beruflichen Gymnasium im Fachbereich Datenverarbeitungstechnik und unser Lehrer bringt das so langweilig rüber.
Also echt gut und interessant gemacht :).
LG Blackbacklp
a little late on the scene, but I did always wander how my old buzz box really worked, and why it always conked out on me in the middle of a job. I did however upgrade to an inverter machine which is so much smoother than the old transformer. i do miss it though, I did keep hold of blue (my affectionate name for the transformer) with the hope of making a spot welder, but in the end I donated it to a friend who wanted to "get into" welding. I must say that although your knowledge of electronics far outweighs mine, I don't feel as confused as I thought I was after watching. thanks for explaining this machine and I hope you managed to build an AC/DC gtaw in the end.
You Sir are a GOD, what is it like walking around us intellectual mortals?
actually there is another reason the transformer heated up so quickly. during normal usage the cables, clamp, clamp ground connection and the wire electrodes have a lot more resistance probably 10x more than the two short fat wires you bolted to the outputs, which of course caused more than the 140 max amps that the transformer is rated for. comparing the two fat wires to the secondary wires shows that difference. also most welders are sole with 20% duty cycle.apart from my above comment, I think I agree with all the good compliments about your videos. excellent understanding of the subject and very clear and precise explanations. thanks for sharing. I am looking forward to the "reverse engineering" video of the inverter welder.
Very well done.
so i watched this video yesterday and i was thinking about how to build a inexpensive welder. the idea i have involves 4 mots. i had seen a video where a fellow glues two mots together and ran them at the same time on one primary. this may be the concept we need here. instructions are simple. cut them in half and take out the high voltage secondaries of two and completely gut the other two. in pairs of twos, glue or weld the two e cores together to make two double size mot transformers. im from the US so run in series for 240 or parallel in phase for 120 unless the primaries are already meant for 240 then run in parallel. im gonna do some exparimenting. cheers.