BIFRC spot welder small case
Description
This is a case for a BIFRC battery tab spot welder PCB with two versions. BIFRC_small_case_pigtail.stl BIFRC_small_lid_pigtail.stl The above use cables emerging from the case to plug into an automotive jumpstarter using an EC3 type connector instead of the original XT60 jack (third photo). BIFRC_small_case_XT60.stl BIFRC_small_lid_XT60.stl The above are designed to use the original XT60 jack that comes with the BIFRC card (other photos). The case was shaped fit a corner of an emergency car jump starter, which I no longer use. It's unique. I like it. I added a 1F 16.2V capacitor array (six 6F@2.7V capacitors wired in series across the power leads) under the PCB to improve the weld, but didn't help. It shows in the photos, but I've removed it. An old RJ11 telephone jack is used to attach to a foot pedal via an old telephone cord (I used https://www.thingiverse.com/thing:3152310). The jack is wired to the "KEY" terminals on the BIFRC. You will need to "adjust" the jack (shave the sides) to make it fit. I added 6mm bores in the right side of the case for storing the welding probes when not in use. All screw holes are generic 2mm bores. I used whatever small (5-10mm) self-tapping screws I had on hand to attach the PCB and the lid. I printed with 0.1mm (CTC) and 0.12mm (Ender 3) resolutions, using PLA@220C with supports, no raft, no brim, 20% infill in a hex/triangle pattern. Print the lid piece with no ceiling or floor layers to expose the infill grid. -- TL:DR -- I found that a 6000mAH 50-100C LiIon RC vehicle battery works better than the jump starter. It doesn't need the supercap stage which didn't work very well. The advantages of this design are: o Probe storage is built in, though stiff cables still dangle o It is small enough to toss in a toolkit o The battery is not dedicated to the welder, you can detach it for other uses Problems with this designs are: o There is no power switch, you must unplug the battery to turn it off o The LEDs and programming button are not very accessible o The unit is so light that the welding cables drag it around There's not much you can do about the lack of a power switch with this approach. These spot welders are very sensitive to resistance in the power circuit (which is why you MUST use heavy gauge wire, and good tight connections--screwed or soldered--EVERYWHERE). If LED and button accessibility is a problem, you could just leave the top off. There is also my large case at https://www.thingiverse.com/thing:4837491
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