Made an electronic controller/regulator for TIG water pump

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So I was dinking around today and threw together a simple adjustable and regulated electronic water pump controller.I had been giving my TIG's 12volt water pump something like 3.5volts in order for it to make 50ish psi, the problem is the pressure would vary a bit as water temp changed and whatnot.This new system monitors a cheap 0-100psi pressure sensor on the pump outlet and adjusts the PWM (or drive power) to the pump to maintain a desired set point. The set point is adjustable from 0-100psi using the potentiometer. Pump is run at full power upon initial startup to quickly achieve the desired set pressure, then it's ramped down to a less aggressive value as it's maintaining pressure.This system is very efficient; it uses like 15 watts to maintain 60psi. There is no return line or other wasted energy. Pump life is also maximized because it's only being driven at small percentage of it's rated power and motor RPM in order to maintain the desired pressure; this also makes it much quieter.I plan on adding a temperature sensor to the torch outlet so that a very low (and quiet) coolant flow can be maintained until heating is sensed, then the pump will ramp up to the working set pressure and return to idle once cooled. The battery and whole setup is temporary until i can make a dedicated circuit for it.Last edited by MikeGyver; 11-28-2014 at 02:13 AM.Welding/Fab Pics: www.UtahWeld.com
Reply:I did something like that with the water injection on my diesel.I used a 0.65L air bladder accumulator tank, for an RV, only cost about $30. I set the pressure on the switch to just above the desired out put pressure and set the water pressure regulator.If I remember right the pump runs for about 5 to 8 seconds, fills up the accumulator and shuts off for about 30 seconds, while putting out constant water pressure and volume.I read the pump could burn up if its supplied with less than 9 volts, or cycled continuously or ran continuously. I did that because with out an accumulator tank the pump cycles on and off rapidly.The controls that turn the diesels water injection pump on and off are totally different then what you would use for a tig torch obviously. Anyone running a simpler setup and is having a rapidly cycling pump problem might want to try what I did.Last edited by mad welder 4; 11-28-2014 at 01:18 AM.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Looks like you up graded to a nicer welder. Have you had a problem with the cooler setup up getting to hot at the torch with no exchanger and fan? When welding bead after bead on aluminum? I'm trying to get some info so I not shooting in the dark when I build mine.
Reply:Originally Posted by motolife313Looks like you up graded to a nicer welder. Have you had a problem with the cooler setup up getting to hot at the torch with no exchanger and fan? When welding bead after bead on aluminum? I'm trying to get some info so I not shooting in the dark when I build mine.
Reply:Ok cool. Thanks mike. Why not just run a carbonater motor and procon pump tho? That was going to be my plans
Reply:Originally Posted by motolife313Ok cool. Thanks mike. Why not just run a carbonater motor and procon pump tho? That was going to be my plans
Reply:Like it Mike, can't make out the chips you used... microcontroller or, don't tell me 555 timer!?!