It has been quite a while since i have posted. Well i finally tested the spot welder controller about a week ago. It worked perfect the first time, no tinkering required. I have a great deal of control over the weld. For example i can weld two peices of 24awg stainless wire -Length-Wise-. Or i can burn a hole through two peices of 22gauge stainless sheet.
I am considering changing the power factor method. At the moment i simply wait for the zero crossing of the mains and then enable the current transformer and begin to count consecutive waves. This works, but it seems to be very peaky. If i evenly distribute the ratio to 1 second it should distribute the heat more evenly. At the same time this will give me the ability to specify another control parameter. I will be able to adjust the term of the of ratio so that i can fine tune the weld.
I have no pictures at the moment.