Auto Powered Arc Welder

In simulator, the variable resistor and coil is not set to correct values. one manufacturer below sells the generators that can weld. https://www.zena.net/htdocs/alternators/alt_inf.shtml War surplus aircraft generators of the past rated at 24 volt and 200 amp was mounted to car engine under the hood and when engine speed turned generator 2500 to 4000 rpm could power a 5/16 inch diameter welding rod. Connections to generator.  The left SPST switch is where connection to A terminal on the generator is and B is the power output.  Both the D and E terminals are connected together and go to the welding ground clamp(SPST) on the far right (welding terminals). The ARC Stabilizer is where the coil is shown.  The core is 2 inch Piece of cold rolled steel at 5.5 inches long wrapped in layer of insulating cloth.  Next comes four layer of 4 gauge enamel coated copper wire wrapped on the core and each layer being separated by insulating cloth. Wrap completed core with tape to make sure wrap stays tight.  Leave about 9 inches of wire on each end to wrap to make connections with. All lines are 4 gauge wire except the lines to the Rheostat (variable resistor) can be 14 gauge wire.  Also, a throttle control for engine speed is needed. For continuous welding on big job connect air horn to engine intake to suck air through the generator for cooling. Experimenting with the welder will show where to make marks to set the control range.

published 6 years ago