'' Toy '' Welding Machines

Overview of compact welding machines: models, characteristics, recommendations for the use of devices and welding.

Accessories of the welder (welding machine, mask, electrode holder with electrode, clamps, brush-hammer, mittening)

You can independently make a solid construction from a metal corner or a channel: a cabinet for a tool or gas cylinders, a frame of a bench or a greenhouse, a gate or a wicket, repair the garden equipment is most convenient with welding. Usually, at the mention of this process, the following associations arise: a bulky welding machine on wheels and bright outbreaks with a spark brake, from the look at which bunnies jump in the eyes. "

If necessary, to purchase a welding machine, many embarrass the impressive dimensions and other inconveniences to the use of this "monster" in the household. It is unlikely that someone will deliver a special pleasure to use the Swaris welding machine, transferring it for two metal handles on the sides, with weight 35kg and sizes of 310280510mm.

Recently, household welding machines appeared on sale, which are so less industrial in weight and sizes that seem to be almost toy. They can be transferred for a special handle or on the strap over the shoulder without much effort. Uvars will not be problems when highlighting a place to constantly storing such an apparatus. Working with him is so simple that every wishes can master the art of welding.

The width of the weld swaying dependent on the diameter of the arc welding electrode is based on the phenomenon of the electric arc, in which the edges of the welded metal parts are melted with an arc discharge between the electrode and the metal at the connection site. With the gradual movement of the electrode along the welded edge of two parts, separate welding points merge into seam. At the same time, it is necessary to maintain a certain gap between the electrode and the welded edges, since when they are touched, a short circuit occurs, and when the arc is too much a gap.

In everyday life, manual arc welding or abbreviated RDS received the greatest distribution. It is accompanied by melting the electrode in the form of a metallic rod with a special coating when using AC or DC. It is also referred to as welding with a melting single electrode, and abroad is reduced. Manual welding is called because the ignition of the arc and maintaining its stable length, the movement of the electrode as the welder itself is completely performed on the combined parts to form the seam. This article we will restrict ourselves to the consideration of small-sized welding machines weighing up to 20kg (this makes it possible to transfer them to one hand) designed to work from the power supply voltage of 220V, which is available in each house.

Welding electrodes are extorted almost different from each other, but are intended for welding of different materials in the arc area, it usually reaches 6000-7000s and is determined by the power of the welding current, which with a limited weight of the welding machine does not exceed 160-200a. To achieve this current strength, the voltage at the outlet of the welding machine is reduced to 48-90V (idling stroke voltage), this is enough to ignite the arc and safe for the life of the welder. The voltage is reduced by a lowering transformer, which is an integral part of the welding machine. The greater the current of the current with sufficient Uhh, the greater the electrode diameter, and the greater the diameter of the electrode, the more massive parts can be welded. Below are the exemplary ratios between the thickness of the welded metal, the diameter of the electrodes and the power of the welding current.

Metal thickness, mm	2.	3.	4-5	5-10.
Electrode diameter, mm	2.	3.	3.	four	four	five
Welding current force, and	40-80	80-120	100-150	160-200	160-210	180 or more

To ensure that current strength, the core of the transformer is made by the massive, and the wire of the secondary winding (the section is more than 10mm2). The current strength during welding of different materials has to be selected from the ranges given in the table, which is why the device must be provided for changing the current force, and one or more fans are embedded to exclude overheating. All this increases the weight of the household welding machine, so manufacturers have to invent ways to reduce it.

Inverter welding rectifier of the Technology-165 model of the company Telwin is a simple way to limit the time of the transformer. The special indicator Monpectivity of the load is measured in% in relation to the welding cycle (this cycle is 5 minutes, and in Europe - 10 minutes). For example, with Mon = 60%, the process is carried out as follows: 3-minute welding, 2 minutes - cooling of the transformer, then the welding cycle is repeated, and with mon = 20% - 1-minute welding, and the 4 minutes of cooling the transformer. This indicator should be given in any passport to the welding machine, and with the maximum power of the welding current for each device PN = 20-60%, and with the smallest strength of the PN = 100% and provides continuous welding.

However, striving to reduce the transformer idle time, you must not forget that the process interrupt is sometimes just necessary. First, for the periodic installation in the electrode holder of the new electrode instead of used, and, secondly, after 3-5 minutes of continuous welding, it usually arises the need to prepare parts for further operation. With long welding, for example, bleeding from the grid "Rabita" with a corner frame, these breaks interfere. In order for the master does not get carried away with welding and not burned the transformer, many devices are equipped with thermal protection devices for automatic shutdown from the power supply in case of overheating.

The welding transformer of the PARVA-165E model of the company DecaProduce is easier than the RDS on a constant current, since in this case the arc is less affected by the frequency of the network voltage. To convert the current from the variable to a constant after a transformer, a semiconductor rectifier is installed, to which the elements are added to smooth the pulsations of the straightened current. All this significantly increases the weight and reduces the reliability of the device. But there are also its advantages: the Svetshna seam has more "native" metal parts than the additive metal of the electrodes, as a result of which the amount of scale is reduced and, as a result, a better comparison compared to the RDS on alternating current is provided. The cost of the work and the flow of electrodes is also reduced. Such an apparatus is called a welding rectifier. It is easier for them, but it costs it more expensive than the welding transformer by 1.5-4 times.

Inverter welding rectifiers (inverters) are increasingly distributed, in which before amplification, first increase the frequency of alternating current to 10-90kHz. The weight and sizes of high-frequency transformers are significantly less than their 50-hedze fellow. This feature allows to significantly reduce the dimensions of the entire inverter compared to conventional welding transformers and rectifiers. The current after the inverter is practically permanent and does not depend on the oscillations of the length of the arc and voltage, so its strength can be adjusted smoothly and pick up quite accurately. The arc can also be selected from the very "soft", which is easily "stretched" to "coarse", which is commonly used during metal cutting. This allows even a non-professional easy to master the welding, including "capricious" aluminum and copper alloys, or high-alloyed, for example, stainless steel.

To check the quality of the seam, remove the scale with a hammer welded inverters of small size and weighing up to 10kg, they can be worn on the strap over the shoulder and connect to the total electrical network through the fuse on 16a, of course, with the mandatory grounding of the housing. But the cost is the highest: 4-9 times higher than welding transformers. In the Russian market, you can find all these types of welding machines for the RDS of the French company SAF, Finnish Kemppi, Austrian Fronius, Italian Cebora, Telwin, Deca, Swedish ESAB, American Miller, as well as Russian manufacturers "Evma", LINKOR TOO, Tor, OOO, Nevskaya Electrical Company JSC.

The efficiency of the device is characterized by the efficiency (efficiency) in% (than it is closer to 100%, the cheaper the welding costs), and the power factor (COS) (it should be as close as possible to one). It should be noted that the efficiency and COS characterize the care of the design of the welding machine, so not all firms lead these values ​​in the passport on the machine.

To regulate the welding current force, devices with controls and a scale of the device on the panel of the apparatus are used, contrary or in amperes, or in the ranges of the ranges (1,2,3, ..), or in the diameters of the electrode. Vni most simple models The current strength can be changed only stepwise, and more complex, smoothly, using a rotating handle.

Neverness (not fully woven weld) A number of models have a cooling flow device of the current: first set the corresponding range of current change in the switch to the switch, and then more accurately select the desired value within this range by the rotating handle. Such devices increase the cost of the welding machine by 15-20%. Sometimes an ammeter is installed on the panel to fix the accurate welding current value.

The resource of household welding machines is designed for 250-350 hours of operation, after which preventive repair is usually required (rewind or replace the burnt transformer, replacing the switch or welding current regulator, etc.). Industrial portable devices (Transpocket1400, Master1500, Caddy130) will serve without repair much longer, but they are significantly more expensive than residents. For visibility to the foregoing, comparable "SWARIS" welding transformer with a welding rectifier "Terminator". The "Terminator" provides a higher power of the welding current during dimensions in 3.5rd and weight almost in the 3rd of smaller than that of the "Swarisa", while maintaining the ability to start the car engine, but it is worth such a device in almost 2 times more expensive.

Welding electrodes

The most moves are universal welding electrodes of the corresponding diameter with rutile coating of the brands of ANO-3, ANO-4, MR-3, MR-4, OGSC-3, OGSC-4. They are suitable for welding structures from carbon and low-alloyed steels by variable and direct current. For welding of high-alloy steels (stainless, heat-resistant), aluminum and its alloys, copper and its alloys, not only special electrodes intended for the welding of direct current are used, but also comply with a certain polarity of their inclusion specified on the package - direct or reverse. If you do not exclude the ability to weld these materials in the household, then when buying a welding machine, ask if the appropriate electrodes are provided for it.

Recommendations for the use of welding machines

• In the instructions on the use of some welding machines, instead of the PN indicator, the PV-Duration of the inclusion is given. Let it be bothering you: its value completely coincides with the value of the mon.
• Inverters are more sensitive to a reduction in voltage in the network than welding transformers and rectifiers: when a voltage is reduced by 15%, such a device is simply not started.
• Any apparatus should be able to periodically use (at least once in 3 months), since in the absence of current in its individual elements, for example, in capacitors, processes occur, which reduce the efficiency of the device.
• With the preferential use of one diameter electrodes, for example 3mm, it is better to purchase a welding machine, which for them Mon = 100%.
• Install a fuse designed for a current of at least 16a, and a cross-section of a cross section of at least 2.5mm2 at the maximum power of the welding current of the up to 140a, or a separate panel with an electric meter, designed for current of at least 40a, for example, the CO-I-446M model, and the summory A wire with a cross section of at least 6mm2 at the maximum power of the welding current from 180 to 300a.
• When choosing a place for a shield, keep in mind that the length of the connecting cable from this shield to the welding machine should be limited. It is necessarily indicated in the passport on the device and is usually from 5 to15m.

Recommendations for welding

• The arc brightness is about 10 thousand times higher than those acceptable for the human eye brightness of the light, so the welding uses protective glass, which makes it uncomfortable to monitor the process and, especially at the time of the ignition of the arc. A modern welder mask is equipped with a protective glass "chameleon" with a touch effect: the degree of transmission of the light decreases sharply when the arc is igniting, and this degree of bandwidth can be adjusted by itself.
• The welding current depends on the voltage of the network and when the latter falls to 180-200V should go to the welding electrode of smaller diameter.
• If there is an ammeter on the control panel of the welding machine, you can remember the exact value of the selected current during the welding of any metal and in the future immediately set this value with such works by reducing the time to select the mode.

Portable devices by 220 V for manual arc welding solitary electrode

Firm	Model	Need Power, kW	Type of current	Current strength, * a	Uhh, B.	Cosj.	Mon,% **	Efficiency,%	overheat protection	Weight, kg	Dimensions, see
Cebora.	Dallas-40	5.5	Variable	50-120	-	-	twenty	-	there is	16.5	342632.
LINKOR LLP	TDM-163.	5.5	Variable	80,120,160	60.	-	twenty	70.	Not	fifteen	361922.
Helvi.	Util 161 Turbo.	5,2	Variable	50-160	-	-	twenty	-	there is	eighteen	352524.
Saf.	SAFOR-140.	5,7	Variable	65-140	48.	-	twenty	-	there is	sixteen	462832.
Deca.	Parva 165E.	5.0	Variable	40-160	48.	-	twenty	-	there is	16.5	392128.
Telwin.	Nordica 161.	4.0	Variable	55-160	49.	-	twenty	-	there is	17.	284334.
TOR	Terminator	5.0	Constant	80, 100, 140, 180	80.	-	60.	-	Not	13	202525.
Saf.	Presto 165.	5.0	Constant	5-160	48.	-	60.	-	there is	13	471754.
SIRGOS	Adonis-3.	5,1	Constant	35-160	80.	-	60.	84.	there is	17.	163352.
Kermanri.	Master 1500.	6.6	Constant	15-150	80.	0.75	twenty	80.	there is	10	391629.
AO NEC	Electron-125.	-	Constant	40-125	90.	-	thirty	60.	there is	9.9	172535.
Telwin.	TECHNOLOGY 165.	5,2	Constant	5-160	98.	0.72	40.	82.	there is	9.3.	391629.
Deca.	MOS 160.	5.0	Constant	5-160	60.	0.9	25.	84.	there is	nine	441525.
Esab.	Caddy 130.	4,4.	Constant	3-130	60.	-	35.	71.	there is	eight	301620.
Cebora.	Baby Rod 130.	4,4.	Constant	12-130	-	-	35.	-	there is	5,8.	143023.
Fronius.	Transpocket1400.	4.6	Constant	5-140	93.	0.99	60.	88.	there is	4,2	311120.

* The values ​​of the current strength specified through the comma can be installed on the welding machine stepped, and through the dash - smoothly or smoothly accommodated.

** PN values ​​are given for maximum welding current.

When preparing a report, information from GOST 95-77, GOST 304-82, GOST 9466-75 and GOST 9467-75 are used.

The editors are grateful to the company "Tor" for help in preparing a report.