Spot Welder (not yet commissioned)

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Induction Required

This equipment requires an induction prior to use. For your own safety and to avoid damage to the equipment do not attempt to use it until you have been inducted.

Burn Hazard

This equipment is hazardous to the user or those around them, take care during use.

Electrical Hazard

This equipment is hazardous to the user or those around them, take care during use. Metal jewellry, watches, and clothing with metal zips must be removed before use. The area must be cleared of metallic items.

Lithium Battery Hazard

If using the welder with lithium batteries they have their own set of risks. Fire if they are punctured or short circuited. Thermal runaway. Cooling the cells is the best way to prevent neighbouring cells from also catching fire. Do we want to suggest water for this? Otherwise a bucket of sand can be used to limit the impact of the fire somewhat When working with lithium batteries care must be taken to avoid metallic objects coming into contact with the cells as this could cause a short circuit. It is advisable to cover the ends of cells that are not currently being welded with tape to prevent accidental contact. .

PPE Required

This equipment requires the use of eye protection protection and gloves during use.

A spot welder operates by passing an electric current through metal sheets, generating heat at the point of contact and causing them to fuse together. This process creates localised welds known as “spots,” characterised by high strength and minimal distortion.

This is our spot welder: *Picture of it*

What Can I Use the Spot Welder For? The spot welder is for attaching thin pieces of metal together. This is commonly done in the assembly of lithium batteries. Other uses of a spot welder

kWeld Operation Manual - External Link kWeld Assembly Manual - External Link

Setup and Preparation for a Spot Welding

Clear the area of of metallic objects that could cause an accidental short.
Ensure the spot welder is securely connected to a suitable power source and turned on. Provide more detail about the order in which is should be turned on. Plug in kettle lead, plug in foot pedal, plug in welding pen, turn on switch below kettle lead. Include pictures of the kettle plug and switch, foot plug, and welding pen jacks.
Material Preparation: Clean the surfaces of the metal sheets to be welded, removing any dirt, oil, or debris that could interfere with the welding process.
Adjustment: Adjust the spot welder settings, including the welding current and duration, based on the material type, thickness, and desired weld strength.

Adjusting the Welder Settings

Bullet point
Another bullet point
Yet another bullet point

Making a Spot Weld

Clamping: Position the metal sheets between the electrodes of the spot welder, ensuring proper alignment and contact.
Activation: Activate the spot welder to initiate the welding cycle, applying pressure and current to create the weld.
Cooling: Allow the welded area to cool sufficiently before removing the electrodes, ensuring the integrity of the weld joint.

After spot welding

Inspect the weld for quality and integrity, addressing any defects or inconsistencies as needed.
Clean the electrodes and workspace to maintain optimal welding conditions and prevent contamination in future welds.
Turn off
Clear the area of left over metal pieces
Place the main box back on the shelf?? It must be positioned in a way that allows the cooling fan to draw in air to cool the discharge resistor.

Spot Welder Components

The box consists of multiple components, many of which from keenlab,
kWeld complete kit
kCap ultracapacitor module
kSupply high current voltage regulator and charger
Power supply
Power resistor
Cooling fan
Think it's the Fujitsu DPS-800GB
U.S. Solid 70B Integrated-style Welding Pen https://www.sunkko.net/products/u-s-solid-70b-integrated-style-welding-pen.html

Maintenance

Some content