Hello everyone! Soon I’ll be presenting my new project — MyWeld 2.0 PRO, an Arduino-based spot welding machine. This device is powered by supercapacitors and supports both single-pulse and dual-pulse welding modes. It also features manual and automatic operation modes.
The project includes a wide range of protections, self-diagnostics, and flexible settings to adapt to different welding needs.
This is a completely free project. No subscriptions. No registrations. Just download the archive and build it yourself!
MyWeld V2.0 Spot Welding Machine Project Overview MyWeld V2.0 is a DIY spot welding apparatus designed to operate from two high-capacity supercapacitors connected in series (each 3000 F). This portable welding device is capable of delivering one or two precisely-timed welding pulses, making it ideal for tasks like battery tab welding or small-scale metal bonding. The system offers both manual and automatic operating modes, along with adjustable pulse parameters and built-in safety features to ensure reliable performance. Adjustable Welding Pulse Parameters MyWeld V2.0 allows fine-tuning of the welding pulse timing to achieve optimal weld quality. The key pulse parameters are: P1 (First Pulse Duration): Adjustable from 1 to 50 milliseconds (in 1 ms increments). This is the initial welding pulse. T (Inter-Pulse Delay): Adjustable from 1 to 50 milliseconds (1 ms step). This is the delay period between the first and second pulse. P2 (Second Pulse Duration): Adjustable from 1 to 50 milliseconds (1 ms step). This is the follow-up welding pulse (if a second pulse is used). These settings enable the user to configure a single-pulse weld or a dual-pulse weld. For example, a short P1 pre-pulse can be used to clear oxidation or preheat the material, followed by a brief pause (T) and then a stronger P2 pulse to complete the weld. All timing is controlled by the microcontroller to ensure consistency regardless of how long the button is pressed. Operating Modes: Manual and Automatic The device supports two operating modes, MANUAL and AUTO, to trigger the welding process: Manual Mode: In manual mode, welding is initiated by the user pressing the Start button. Upon pressing the button, the device automatically executes the configured weld sequence. The sequence consists of the first pulse (P1) for the set duration, an optional short pause (~10 ms), the main delay (T), and then the second pulse (P2, if configured). The entire pulse sequence runs automatically and independent of the button press length – even if the Start button is held down, the system will deliver only the timed single cycle of pulses and then stop until the next press. This ensures a controlled and repeatable weld each time. Automatic Mode: In automatic mode, the welder is triggered by the contact of the welding electrodes, rather than by the button. When the electrodes touch (shorting together on the workpiece), a built-in delay S (configurable from 0.3 to 2 seconds) begins. Once the delay S has elapsed, the device automatically fires the weld sequence (P1 – T – P2). This allows for hands-free operation: you can position the electrodes on the materials to be welded, and the weld occurs after the set delay. If the electrodes are separated during the delay period S (for instance, if contact is lost or you decide to abort), the welding sequence is cancelled and the timer resets. The machine will then wait for a new electrode contact to initiate the next weld cycle. This mode is useful for achieving consistent timing when making multiple welds, as you simply bring the electrodes together and let the device handle the rest after the short delay. Power Supply and Safety Features MyWeld V2.0 is designed with a robust power supply system and multiple safety protections to prevent damage to the device and ensure user safety: Supercapacitor Power Source: The welder is powered by two supercapacitors in series (2S configuration). When fully charged, the combined voltage of the capacitors is about 5.6 V. This low-voltage high-current power source is what provides the intense pulses of current for welding. It’s important to maintain the supercapacitors within a safe voltage range for reliable operation. 15 V Boost Converter for MOSFET Drive: An internal DC-DC boost converter steps the capacitor voltage up to ~15 V to supply the gate driver for the MOSFET switching transistors. This higher gate drive voltage ensures the MOSFETs (field-effect transistor switches) are fully turned on during the weld pulses, minimizing resistance and heat. If for any reason the boost converter’s output falls outside a safe range (below 10 V or above 18 V), the system’s protection will engage: a warning message is displayed, and the welder is temporarily disabled (it will not respond to the Start trigger) until the gate drive voltage returns to the acceptable range. This prevents improper MOSFET operation due to under-voltage or over-voltage conditions. Supercapacitor Low-Voltage Cutoff: To protect the supercapacitors (and the control electronics) from an excessively low charge, the device monitors the capacitor bank voltage in real time. The bottom line of the LCD acts as a voltmeter, continuously displaying the current supercapacitor voltage. If the voltage drops below 4.5 V, the system recognizes this as an unsafe, deeply discharged state. In this case, a “LOW” indicator will appear next to the voltage reading on the display, and the welder will not execute a weld (the Start function is locked out) until the capacitor voltage is brought above the 4.5 V threshold. This prevents the controller from operating unpredictably at low voltages and protects the capacitors from being driven into an unsafe discharge level. False-Trigger Prevention: Both the MOSFET driver voltage protection and the supercapacitor low-voltage cutoff have a built-in delay of about 1.5 seconds before they activate. This means that the fault condition (out-of-range voltage) must persist for 1.5 s continuously before the protection triggers. This delay is intentional to avoid false alarms or nuisance trips due to very brief voltage dips or spikes. Only sustained under-voltage or over-voltage conditions will disable the device, ensuring that normal transient conditions during welding do not interrupt operation. Startup Self-Test and Backlight Control MyWeld V2.0 includes additional features to enhance reliability and usability: Startup Self-Test: Upon powering up the device, it performs a comprehensive self-test routine that lasts approximately 15 seconds. During this initialization, all major functions and safety circuits are checked to confirm they are working properly. This power-on self-test helps catch any faults before actual welding begins, thereby improving safety and reliability each time you use the welder. Adjustable Display Backlight: Version 2.0 of the project introduces an adjustable LCD backlight brightness feature. The 20x4 character LCD’s backlight can be set to levels 0 through 5, allowing you to dim or brighten the display as needed. A setting of 0 turns the backlight off, while 5 sets it to maximum brightness. This adjustment can be useful for saving power or improving screen readability under various lighting conditions. Main Components The MyWeld V2.0 spot welder is built using commonly available electronic components, making it feasible for hobbyists or makers to assemble. The primary components include: Microcontroller Board: Arduino Nano (serves as the main controller running the firmware and handling user input, timing, and safety logic). Display: 20x4 LCD module (2004) with an I2C interface adapter (for showing the menu, parameters, mode status, and voltage readings). User Input Device: Rotary encoder with an integrated push-button (used for navigating settings, adjusting pulse timings, switching modes, and starting the weld in manual mode). Additionally, high-power MOSFETs, a gate driver, supercapacitors, and other supporting circuitry (not listed above) are used to complete the welder’s power circuit and control system. All these components together form a compact and efficient spot welding unit. Conclusion and Project Status All features of the MyWeld V2.0 have been tested, and the device is confirmed to be working reliably. The design is stable, with only a few minor software quirks noticed, none of which affect the welding performance or safety. This project demonstrates a practical and effective spot welding solution using supercapacitors, and it can be a useful tool for electronics enthusiasts and battery pack builders. If you found this project interesting or useful, please consider showing your support (for example, by giving it a “like” or sharing it). Such feedback is greatly appreciated and motivates the continued development of open-source DIY projects. Thank you for reading about MyWeld V2.0, and happy welding!
I have decided to develop a powerful spot welding machine. Please review and provide feedback on what should be changed or improved in version 1.0.
P.S. The project will be available for download COMPLETELY FREE, without donations or any other payments (as always). Once testing is complete, I will upload all source files, the full schematic, PCB, and sketch.
Main Features and Options
Dual-Pulse Spot Welding Machine "MyWeld" V1.0 (Software Version 1.3)
Project Components
Arduino Nano board
LCD 20x4 display with I2C interface module
Rotary encoder with button
Interface
P1 – Duration of the first pulse (adjustable from 0 to 50ms)
T – Delay between pulses (adjustable from 0 to 50ms, with an additional fixed 10ms delay to prevent operational issues if "T" is set to 0)
P2 – Duration of the second pulse (adjustable from 0 to 50ms)
If only a single pulse is needed, simply set the second pulse duration to zero.
Light on/off – Turns the display backlight on or off.
MODE AUTO/MAN (Available in version 1.1; AUTO mode is not available in version 1.0)
In "MAN" (manual) mode, welding starts after pressing the "START" button. The machine generates pulse "P1," followed by the optional 10ms delay, then the main delay "T," then "P2." The cycle ends until the button is pressed again. The duration of the button press does not affect the welding sequence or the timing of pulses and delays.
In "AUTO" (automatic) mode, a parameter "S" (adjustable from 0.1 to 2 sec) appears next to this setting. In this mode, welding starts automatically when electrode contact is detected. After electrodes touch, the process begins after the delay set by "S." If the user changes their mind and breaks electrode contact before "S" elapses, welding will not start.
Voltage Monitoring & Safety Features
A voltmeter on the display's bottom line shows the power source voltage.
If the voltage drops below 4V and remains there for 1.5 sec, the device enters low-voltage error mode, displaying "LOW." In this case, the "START" button is disabled until the voltage exceeds 4V.
The 1.5 sec delay prevents false triggering due to temporary voltage drops during welding.
15V Power Line Protection
The 15V power supply is needed for the MOSFET gate driver and is generated from the low-voltage power source.
If the 15V converter fails, gate voltage may be insufficient, potentially damaging the transistors.
A protection system monitors the control voltage (should be between 10V and 18V). If it goes outside this range for more than 1.5 sec, protection is triggered:
All controls and power transistors are disabled.
The display clears and shows "DC 15V PROBLEM! DANGER! CONTROL VOLTAGE ERROR <10V >18V."
The buzzer emits periodic beeps at 1Hz.
Power Source & Key Components
Power source options:
Two 3000F supercapacitors in series
2S Li-Po high-current battery (5000mAh or more, with a discharge rate of 50C or higher)
MOSFET Selection
Must have a drain-source voltage rating of at least 30V.
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1 month ago | [YT] | 11
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Kasyan TV
Hello everyone!
Soon I’ll be presenting my new project — MyWeld 2.0 PRO, an Arduino-based spot welding machine.
This device is powered by supercapacitors and supports both single-pulse and dual-pulse welding modes. It also features manual and automatic operation modes.
The project includes a wide range of protections, self-diagnostics, and flexible settings to adapt to different welding needs.
This is a completely free project.
No subscriptions. No registrations.
Just download the archive and build it yourself!
6 months ago | [YT] | 138
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Kasyan TV
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Kasyan TV
MyWeld V2.0 Spot Welding Machine Project
Overview
MyWeld V2.0 is a DIY spot welding apparatus designed to operate from two high-capacity supercapacitors connected in series (each 3000 F). This portable welding device is capable of delivering one or two precisely-timed welding pulses, making it ideal for tasks like battery tab welding or small-scale metal bonding. The system offers both manual and automatic operating modes, along with adjustable pulse parameters and built-in safety features to ensure reliable performance.
Adjustable Welding Pulse Parameters
MyWeld V2.0 allows fine-tuning of the welding pulse timing to achieve optimal weld quality. The key pulse parameters are:
P1 (First Pulse Duration): Adjustable from 1 to 50 milliseconds (in 1 ms increments). This is the initial welding pulse.
T (Inter-Pulse Delay): Adjustable from 1 to 50 milliseconds (1 ms step). This is the delay period between the first and second pulse.
P2 (Second Pulse Duration): Adjustable from 1 to 50 milliseconds (1 ms step). This is the follow-up welding pulse (if a second pulse is used).
These settings enable the user to configure a single-pulse weld or a dual-pulse weld. For example, a short P1 pre-pulse can be used to clear oxidation or preheat the material, followed by a brief pause (T) and then a stronger P2 pulse to complete the weld. All timing is controlled by the microcontroller to ensure consistency regardless of how long the button is pressed.
Operating Modes: Manual and Automatic
The device supports two operating modes, MANUAL and AUTO, to trigger the welding process:
Manual Mode: In manual mode, welding is initiated by the user pressing the Start button. Upon pressing the button, the device automatically executes the configured weld sequence. The sequence consists of the first pulse (P1) for the set duration, an optional short pause (~10 ms), the main delay (T), and then the second pulse (P2, if configured). The entire pulse sequence runs automatically and independent of the button press length – even if the Start button is held down, the system will deliver only the timed single cycle of pulses and then stop until the next press. This ensures a controlled and repeatable weld each time.
Automatic Mode: In automatic mode, the welder is triggered by the contact of the welding electrodes, rather than by the button. When the electrodes touch (shorting together on the workpiece), a built-in delay S (configurable from 0.3 to 2 seconds) begins. Once the delay S has elapsed, the device automatically fires the weld sequence (P1 – T – P2). This allows for hands-free operation: you can position the electrodes on the materials to be welded, and the weld occurs after the set delay. If the electrodes are separated during the delay period S (for instance, if contact is lost or you decide to abort), the welding sequence is cancelled and the timer resets. The machine will then wait for a new electrode contact to initiate the next weld cycle. This mode is useful for achieving consistent timing when making multiple welds, as you simply bring the electrodes together and let the device handle the rest after the short delay.
Power Supply and Safety Features
MyWeld V2.0 is designed with a robust power supply system and multiple safety protections to prevent damage to the device and ensure user safety:
Supercapacitor Power Source: The welder is powered by two supercapacitors in series (2S configuration). When fully charged, the combined voltage of the capacitors is about 5.6 V. This low-voltage high-current power source is what provides the intense pulses of current for welding. It’s important to maintain the supercapacitors within a safe voltage range for reliable operation.
15 V Boost Converter for MOSFET Drive: An internal DC-DC boost converter steps the capacitor voltage up to ~15 V to supply the gate driver for the MOSFET switching transistors. This higher gate drive voltage ensures the MOSFETs (field-effect transistor switches) are fully turned on during the weld pulses, minimizing resistance and heat. If for any reason the boost converter’s output falls outside a safe range (below 10 V or above 18 V), the system’s protection will engage: a warning message is displayed, and the welder is temporarily disabled (it will not respond to the Start trigger) until the gate drive voltage returns to the acceptable range. This prevents improper MOSFET operation due to under-voltage or over-voltage conditions.
Supercapacitor Low-Voltage Cutoff: To protect the supercapacitors (and the control electronics) from an excessively low charge, the device monitors the capacitor bank voltage in real time. The bottom line of the LCD acts as a voltmeter, continuously displaying the current supercapacitor voltage. If the voltage drops below 4.5 V, the system recognizes this as an unsafe, deeply discharged state. In this case, a “LOW” indicator will appear next to the voltage reading on the display, and the welder will not execute a weld (the Start function is locked out) until the capacitor voltage is brought above the 4.5 V threshold. This prevents the controller from operating unpredictably at low voltages and protects the capacitors from being driven into an unsafe discharge level.
False-Trigger Prevention: Both the MOSFET driver voltage protection and the supercapacitor low-voltage cutoff have a built-in delay of about 1.5 seconds before they activate. This means that the fault condition (out-of-range voltage) must persist for 1.5Â s continuously before the protection triggers. This delay is intentional to avoid false alarms or nuisance trips due to very brief voltage dips or spikes. Only sustained under-voltage or over-voltage conditions will disable the device, ensuring that normal transient conditions during welding do not interrupt operation.
Startup Self-Test and Backlight Control
MyWeld V2.0 includes additional features to enhance reliability and usability:
Startup Self-Test: Upon powering up the device, it performs a comprehensive self-test routine that lasts approximately 15 seconds. During this initialization, all major functions and safety circuits are checked to confirm they are working properly. This power-on self-test helps catch any faults before actual welding begins, thereby improving safety and reliability each time you use the welder.
Adjustable Display Backlight: Version 2.0 of the project introduces an adjustable LCD backlight brightness feature. The 20x4 character LCD’s backlight can be set to levels 0 through 5, allowing you to dim or brighten the display as needed. A setting of 0 turns the backlight off, while 5 sets it to maximum brightness. This adjustment can be useful for saving power or improving screen readability under various lighting conditions.
Main Components
The MyWeld V2.0 spot welder is built using commonly available electronic components, making it feasible for hobbyists or makers to assemble. The primary components include:
Microcontroller Board: Arduino Nano (serves as the main controller running the firmware and handling user input, timing, and safety logic).
Display: 20x4 LCD module (2004) with an I2C interface adapter (for showing the menu, parameters, mode status, and voltage readings).
User Input Device: Rotary encoder with an integrated push-button (used for navigating settings, adjusting pulse timings, switching modes, and starting the weld in manual mode).
Additionally, high-power MOSFETs, a gate driver, supercapacitors, and other supporting circuitry (not listed above) are used to complete the welder’s power circuit and control system. All these components together form a compact and efficient spot welding unit.
Conclusion and Project Status
All features of the MyWeld V2.0 have been tested, and the device is confirmed to be working reliably. The design is stable, with only a few minor software quirks noticed, none of which affect the welding performance or safety. This project demonstrates a practical and effective spot welding solution using supercapacitors, and it can be a useful tool for electronics enthusiasts and battery pack builders. If you found this project interesting or useful, please consider showing your support (for example, by giving it a “like” or sharing it). Such feedback is greatly appreciated and motivates the continued development of open-source DIY projects. Thank you for reading about MyWeld V2.0, and happy welding!
8 months ago | [YT] | 183
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Kasyan TV
I have decided to develop a powerful spot welding machine. Please review and provide feedback on what should be changed or improved in version 1.0.
P.S. The project will be available for download COMPLETELY FREE, without donations or any other payments (as always). Once testing is complete, I will upload all source files, the full schematic, PCB, and sketch.
Main Features and Options
Dual-Pulse Spot Welding Machine "MyWeld" V1.0 (Software Version 1.3)
Project Components
Arduino Nano board
LCD 20x4 display with I2C interface module
Rotary encoder with button
Interface
P1 – Duration of the first pulse (adjustable from 0 to 50ms)
T – Delay between pulses (adjustable from 0 to 50ms, with an additional fixed 10ms delay to prevent operational issues if "T" is set to 0)
P2 – Duration of the second pulse (adjustable from 0 to 50ms)
If only a single pulse is needed, simply set the second pulse duration to zero.
Light on/off – Turns the display backlight on or off.
MODE AUTO/MAN (Available in version 1.1; AUTO mode is not available in version 1.0)
In "MAN" (manual) mode, welding starts after pressing the "START" button. The machine generates pulse "P1," followed by the optional 10ms delay, then the main delay "T," then "P2." The cycle ends until the button is pressed again. The duration of the button press does not affect the welding sequence or the timing of pulses and delays.
In "AUTO" (automatic) mode, a parameter "S" (adjustable from 0.1 to 2 sec) appears next to this setting. In this mode, welding starts automatically when electrode contact is detected. After electrodes touch, the process begins after the delay set by "S." If the user changes their mind and breaks electrode contact before "S" elapses, welding will not start.
Voltage Monitoring & Safety Features
A voltmeter on the display's bottom line shows the power source voltage.
If the voltage drops below 4V and remains there for 1.5 sec, the device enters low-voltage error mode, displaying "LOW." In this case, the "START" button is disabled until the voltage exceeds 4V.
The 1.5 sec delay prevents false triggering due to temporary voltage drops during welding.
15V Power Line Protection
The 15V power supply is needed for the MOSFET gate driver and is generated from the low-voltage power source.
If the 15V converter fails, gate voltage may be insufficient, potentially damaging the transistors.
A protection system monitors the control voltage (should be between 10V and 18V). If it goes outside this range for more than 1.5 sec, protection is triggered:
All controls and power transistors are disabled.
The display clears and shows "DC 15V PROBLEM! DANGER! CONTROL VOLTAGE ERROR <10V >18V."
The buzzer emits periodic beeps at 1Hz.
Power Source & Key Components
Power source options:
Two 3000F supercapacitors in series
2S Li-Po high-current battery (5000mAh or more, with a discharge rate of 50C or higher)
MOSFET Selection
Must have a drain-source voltage rating of at least 30V.
Rds-on should be 2mΩ or lower (lower is better).
The maximum drain current should be as high as possible.
Noise Reduction & Debounce Measures
The device is designed to minimize electromagnetic interference in the start button wires (can be replaced with a pedal).
Both hardware and software debounce mechanisms are implemented.
Development Status
As of 13/03/2025:
The final circuit version is V1.0
The final software version is V1.3
Upcoming V1.1 will include AUTO mode.
The circuit and PCB will remain mostly the same.
Major updates will be software-related.
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