kicksurfer – skid plate (DXF model)
2017-04-03
kWeld – electrode set
2017-07-15

kWeld – electronics

99,00113,00

Clear

NOTE: the first batch of products has been shipped and I am currently sold out. I will now allow some time for customer feedback that may result in further improvement. New pre-orders will be accepted by Sept~Oct 2017, and I expect to be able to deliver parts from a second, larger production batch by Oct~Nov 2017.

The assembly and operating manuals are available on this website for download (https://www.kicksurfer.de/index.php/product/assembly-manual/ –  https://www.kicksurfer.de/index.php/product/kweld-operating-manual/). You can purchase them in the shop at no cost as a regular item and will receive a download link.


This is the brain of the kWeld battery spot welder. You purchase a professionally reflow soldered, tested and programmed electronic module.

This product comes in two different flavors:

Without assembly service: a partially completed PCB, plus a few components that are not soldered but enclosed separately instead:

  • the LCD
  • an 11 pin male header to connect LCD and module
  • the potentiometer
  • the dial knob

Choose this option if you wish to solder the remaining components by yourself, or if you plan to integrate this unit into a custom housing and need them located in different places.

With assembly service: choose this option, if you like to receive a fully soldered electronics module.


This product is offered in kit form for builders and makers, of which this item is only one part. You decide which parts of the complete system you want to purchase and which parts you want to source yourself locally. Also, you can decide to purchase the soldering, machining, assembly, and cable confectioning work from this shop, or to take over specific work steps by yourself depending on the tools that you have available.


Hardware specifications:

  • Input voltage for welding: 12V – 30V
  • Extremely rugged MOSFET-based power switch and mechanical current bus design
  • Maximum switch current: 2000A
  • Maximum total cabling length of complete system: 1.0m (this is important because the power switch needs to dissipate inductive energy stored in the cabling when switching off)
  • Power switch internal resistance: 120µOhm
  • Pulse duration hardware watchdog: 250ms
  • Undervoltage lockout for power switch transistors
  • Input voltage, output voltage, switch current, and logic supply voltage measurement
  • Logic supplied directly from battery – no need for a separate auxiliary power supply
  • Screw terminal for external trigger switch
  • Screw terminal for optional external logic supply
  • Logic supply holdup capacitor during pulse firing
  • user interface via an LCD, a dial/potentiometer, and a beeper

Software specifications:

  • Central weld control algorithm uses a Joule metering approach instead of a simple timer, eliminating the need for two-pulse firing and providing more consistent welds – the amount of energy that is deposited into the weld spot is always kept constant
  • Ability to detect a failed weld, and acoustic feedback to the user
  • Calibration procedure to cancel out electrode lead losses
  • Manual mode, triggered from external switch
  • Automatic mode, accompanied with a warning sound and triggered with a 0.5sec delay, once the system detects that both electrodes are in steady contact with the weld material
  • Audible feedback of weld process completion
  • Numeric feedback from an executed weld, assisting the user to achieve best results: deposited energy amount, required pulse time for this energy, measured current flow, measured ohmic resistance of weld spot
  • Simple and intiuitive user interface – just adjust the desired weld energy up to 500 Joules with the dial potentiometer
  • Overcurrent monitoring aborts pulse when triggered, protecting the power switch
  • Battery monitoring between welds
  • Fuse fitness monitoring
  • Firmware update interface

Please also check out

https://endless-sphere.com/forums/viewtopic.php?f=14&t=89039

http://www.eevblog.com/forum/projects/guesses-on-what-i-am-attempting-here

as well as these videos discussing the system:


WARNING:

You are dealing with very high energy levels when using this system, which may result in personal injury or fire when handled improperly. Take appropriate safety measures and use this system with caution. Never leave it unattended while being powered.


Disclaimer:

This product is provided as is without any guarantees or warranty, except where obliged by national law. In association with the product, www.kicksurfer.de makes no warranties of any kind, either express or implied, including but not limited to warranties of merchantability, fitness for a particular purpose, of title, or of noninfringement of third party rights. Use of the product by a user is at the user’s risk.

In no event shall www.kicksurfer.de be liable for any direct, indirect, punitive, incidental, special, or consequential damages whatsoever arising out of or connected with the use or misuse of any product purchased herein. You agree and acknowledge that any product purchased should be used at your own risk and you should assess the risks before purchasing any product or using any product. You agree that in the event that www.kicksurfer.de is deemed liable for any harm caused, the amount which it shall be liable to you shall be limited to the cost of the product.

NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A SPECIFIC PURPOSE, THE PRODUCTS TO WHICH THE INFORMATION MENTIONS MAY BE USED WITHOUT INFRINGING THE INTELLECTUAL PROPERTY RIGHTS OF OTHERS, OR OF ANY OTHER NATURE ARE MADE WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH INFORMATION MENTIONS. IN NO CASE SHALL THE INFORMATION BE CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE.

Weight 0.08 kg
Dimensions 15 x 15 x 5 cm
assembly service

no assembly service, with assembly service