I Want To Make A Mig Mag welder up to 250A

[kruparica]

I want make mig welder (and tig when build mig...) up to 250A 3 phase,but i dont know how to beggin to calculate transformer,and no schematics of Pcb,can someone help?

 

[Bobbes]

I think that buy a (second hands) welding machine is cheaper.

 

[penfold]

There are several websites covering DIY welder construction;

here
here

There are loads of others that google throws up.

That said it would be a lot easier to buy one; if you want to weld things buy a welder, if you want to learn about high voltage/high current electronics build a welder.

 

[kruparica]

Thanks

I want build welder for satisfaction,I am A member Of Mensa...
I want to learn.
Please I need A Calculations for wide range of welders or some books for welding transformer in .Pdf-file
I googling but there are a 200 000 pages of welders 99% for selling welders
Thanks

 

[the snooper]

you will first of all need to find a company that has a 3 phase transformer with a secondary winding capable of generating 250amps and also multiple taps on the primary windings capable of giving you the power range you want at various settings unless of course you intend to build an invertor based machine

 

[drjim]

Buy an old welder which will have the bits in then rebuild it to be better.

 

[kruparica]

I want to winding alone transformer but how i can calculate smal transformer and motors but welding transformer dont know
Yes i have Money for old used or new but i want satisfaction and learn.
Here in Serbia when i living i can not find a old mig (can find chinese trash)

 

[stuvy]

use the chinese one to improve upon to start with if it all works then spend the money on buying new parts to build one.

I think your really gonna struggle to get the knowledge without talking to a manufacturer so that should be your next port of call

 

[R Kraft]

This might help.:http://books.google.com/books?id=fv...opular mechanics transformer building&f=false
You would need to wind 3 small transformers and run one off of each leg of the 3 phase.
The 100% duty cycle point for most of the small mig transformers is just 500w.
Building your own transformer is a lot of work and sometimes materials are hard to find.
In the States copper wire of the size you need used to be sold by the bucket.
To control the output voltage you will need multiple taps on the inputs,a large Triac on the inputs,or a set of SCR/Triac.to phase quadrant switch the output power.
You would also need about 100,000uf of capacitance for the mig circuit.
Mig is DC voltage,Tig for aluminum is AC and usually has a high frequency high voltage superimposed on the waveform to stabilize the arc.
Most people can not just fab up a welder from unrelated parts in an afternoon,and a multipurpose welder would be proportionally harder.
Robert

 

[rtbcomp]

Thanks for the link - I've added it to "Manuals, Books, Websites and Instructional Videos &c" in the Links section.

 

[kruparica]

I need

I need example for calculating welding mig transformer,and schematic of the Board,Thanks

 

[shenion]

There are a lot of transformer design info online.
The Miller weld calculator will tell you the voltages and current ranges you will need.
There are PWM controllers for the wire feed speed control available.

 

[MonsterLandrover]

I would be looking at building a modern solid state machine rather than an archaic design. Transformers have a very bad (most of them anyway) power factor and a inefficient.

If you are as intelligent as you say, there would be more satisfaction building a machine to put the manufacturers to shame.

 

[Wozzaaah]

I've tidied this thread up.
The OP is asking a genuine question, if you can't contribute a sensible answer then please don't post.

Regardless of the complexity, it would be great for him to see this through and have a working machine to show us at the end of it.

 

[amron]

Desining and building an inverter based welder is not an easy task at all. building a welder based on a transformer is not beyond the capabillity of a person that has basic electrical knowledge. I wouldn't go into building the transformer itself, I would have buy one factory made, I've seen on the web quite some time ago an Indian firm that manufactures all sorts of transformes, among them was a 3ph mig welding trafo. all the rest, adding a feeder is not too complicated.
Good Luck.