14VDC to 24VDC @ 100A..how cheap/simple can we get?

JGalt

New member
Yep its a welder. But powered by automotive electrical system instead of mains. So lets say 14V input.

Output needs to be constant current at about 100A, with a maximum voltage of around 24V. The voltage needs to be limited to 30V absolute worst case for safety.

Amperage does not need to be adjustable. One setting, 100A. Thats it!

Amperage can wander around a few amps, doesnt need to be regulated better than say +/- 5A, maybe even 10A.

Does not need to be isolated.

Duty cycle needs to be where it can operate for 30 seconds continuously with a 120second cool down. So 20%.

Input voltage should be regulated by vehicle..probably end up being 13V to 14.5V.

So, how cheap and small can this be made, ball park? And what topology would be best?

I will of course share any work and schematics if I end up making a prototype!! As well as videos showing it operating!
 
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