Hacking an inverter

Other Hardware Device Hacking
1

Hi,
This is my first post so kindly accept my apologies for any mistakes.

I have a welding inverter which is controlled by a MEGA8. I dnt have access to the program of this MC. There is an 5 PIN rotary encoder connected to MEGA8. The push button has some functions. And the CW and CCW rotation increases and decreases the output current.
For some reason, I want to introduce pulsing function and I plan to introduce another Atmega328. The input to this ATMEGA328 will be from the PinA and PinB of the encoder (keeping the other wires intact to make the push button function work) and the output after all the pulsing done by ATMEGA328 will be given as input to MEGA8.

Is it possible or doable project?

2

Yes, I imagine so.

Your username suggests that you have a PhD, if this is true in what subject? What is your knowledge of microcontrollers and electronics?

3

Hello thephdguy

Show us a block diagram.
A well-made picture is worth a thousand words.

4

Hi.
My specialization is in welding. I have very basic knowledge of microcontrollers.

5

Thank you for your clarification. I have answered the question you asked, do you want any other help?

6

Yes i will share the block diagram so that u can provide confirmation.

7

17143123758749100664095835844404
171431237587491006640958358444041920×2560 107 KB

This is the block diagram. I could draw it manually. Please accept my apologies.

8

grafik
grafik1180×765 83.8 KB

1 Like
9

My nephew can weld, in fact he can make anything out of metal. If he asked me to make such a thing then I'm sure I could make one. However, I've not made one and don't intend to make one, so yes, it's possible in my opinion.

I suggest you start by getting a rotary encoder and learning how to read it. Also, use an oscilloscope to learn what the output of an encoder looks like so you know what you have to replicate. When you've done that play around with replicating the output of an encoder. When happy with that link the 2 things together and see if it does what you want.

10

I think it is possible but consider using just one MEGA8. Getting the existing code may not be possible but you can measure what it does and duplicate that. This is reverse engineering, it is not the easiest thing to accomplish but could be a good extra point project for the students.

11

Okay. Thanks for the encouraging words. I just wanted some experienced guidance about its feasibility. I had a discussion with my colleague who said that its not possible and his reasoning was very basic which I obviously was not aware. So I thought better to take an experienced opinion. Since the knowledgeable forum members gave me a positive reply... I will go ahead with a dry run. Many thanks to you all!!

1 Like
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