Finished Dual pulse video

WIRING DIAGRAM

DUAL PULSE CAPACITOR WELDER WIRING DIAGRAM

BILL OF MATERIAL

DUALPULSEbom4

Please note that the following components were used for version 1 and are not necessary to install for version 2. 
Q1, Q2, Q3,
D6, D7
U4
R4, R8, R9, R10, R12, R13, R27
C9

Finished Dual Pulse Welder

The oscilloscope photo above shows a 12.6 Volt, 5Ms and 15.1Ms weld. Both pulses and the charge times is measured between the two purple lines and is 189Ms which is more than 5 welds per second at this setting.

Photo's

 Left to right : Pulse1, Pulse2 and Voltage adjustment

 

This took me way longer than expected and I was hoping to have it done by the end of this weekend. The aluminum brackets that the pcb's are on took me most of Saturday to make. I broke two brackets before getting it right and then had a hard time mounting the pcb without making a short. I finally cut all my hard work off and put a piece of wood between the the two cut offs. Bending, drilling and fitting the copper bars took up all of today.
I did however test the dual pulse before tackling this job and I am very pleased with the results. It works better than expected and you can use any one of the two pulses by turning anyone off or use both. At this moment you get two bleeps when you use the dual pulse and one bleep when you use one pulse, it is very fast though and sounds more like a long and a short bleep. It's things like this that needs a little attention.
I will try and have it finished by next weekend and hopefully get it on youtube.

Just a quick update

I'm done writing the code for the dual pulse and ran it on a simulator but haven't tested it on the welder yet. I took my old welder apart and are in a process of building the new design into that box. I had to cut the Mosfet board and the heat sinks smaller to fit and will post the pictures when I'm done. I was looking into using Joules and Watt Second and not time to control the welder and I will definitely use that to control this welder with a version 3 chip after this one. 
What is the difference? Joule and Watt Second will look at the resistance and adjust the time automatically to make better controlled welds and preventing burning holes when the pressure on the electrodes are not same. It will also give you the exact energy release when you are welding different resistances. 

ALMOST DONE

Well, I'm busy with the dual pulse code for the processor and also a couple of bugs that is p***ing me off :)) I guess everyone is asking "why so many Mosfets?". Many Mosfets in parallel lowers the resistance that lowers the heat and increase the amps. The difference between six of these Mosfets and eighteen is a couple of hundred amps more and a welder that is not going to overheat and burn out. You can also see that I get excellent controlled welds at much lower energy rates than commercial welders out there. I'm also turning this Mosfets on and off at  precise calculated speeds according to the data sheets to prevent them from going up in smoke.
I'm in the process of ordering more boards and will hopefully be done with the programming by the time they come in to make it available to you guys.