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World-Class Battery Welding Solutions

World-Class Battery Welding Solutions

World-Class Battery Welding Solutions

Product catalog summary
Overview: The document presents the Sunstone Omega PA250i battery welding system, designed to enhance battery efficiency by welding copper tabs to steel or aluminum. It is available in three configurations: Stylus, Weld Head, and CNC Table, catering to different production scales.
Configurations:
  • Stylus: Ideal for R&D labs or smaller shops, featuring 5x microscopic optics.
  • Weld Head: Suitable for mid-size production facilities.
  • CNC Table: Utilizes a Janome Cartesian Robot for large-scale production.
Key Features:
  • Dissimilar welding capabilities for various metal combinations.
  • 250 Ws max energy, suitable for welding materials 0.003-0.030” thick.
  • Digital control with a color touchscreen and visual waveform graphs.
  • PLC-ready with 5 outputs/2 inputs for integration into production processes.
  • CNC compatibility and 127 remote schedules for efficiency.
  • WiFi software upgrades and built-in training resources.
  • Available warranties: 1-year or lifetime through the Sunstone Circle.
Specifications:
  • Energy range: 0.01 - 250 Joules; Current range: 6 - 1000A.
  • Pulse arc weld current: 1-1000 Amps; Weld spot diameter: 0.1 - 4.5mm.
  • High-frequency agitation and advanced pulse shaping.
  • Microscope magnification: 5x with UV/IR protection.
  • Touchscreen display: 10” color with multiple language support.
Weld Head Specifications:
  • Pressure range: 30-90psi; Height adjustment: 0-7”.
  • Force weight: 1-14 lbf; Preferred working distance: 1/8-1/2”.
Advanced CD Fine-Spot Resistance Welders:
  • Features include a touchscreen interface, visual graph of weld waveform, and high-precision energy adjustment.
  • Available in four models: 200, 400, 600, and 1200.
  • Recommended weld head for battery applications: WH2, with manual or pneumatic actuation.
Dual Pulse CD Spot Welder:
  • Available in three models: 200, 400, 600, designed for battery pack manufacturing.
  • Features digital energy display, single or dual pulse operation, and roll spot capability.
Sunstone WH2 Weld Head:
  • Offers manual or air actuated options with adjustable pressure and height.
  • Includes a foot pedal for easy operation and accepts 1/4” electrodes.
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Catalog excerpts

World-Class Battery Welding Solutions-1

World-Class Battery Welding Solutions

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World-Class Battery Welding Solutions-2

Weld Copper Tabs and Boost Battery Efficiency The Preferred Battery Welding System for Copper, Nickel, Aluminum Tabs! The Sunstone Omega PA250i battery welding • PLC-Ready. With 5 outputs/2 inputs easily using a pure copper tab to connect your batteries, • CNC Compatibility. Attaches to any CNC table, system can attach copper to steel or aluminum. By you’ll significantly boost power cell efficiency. Avail- able in three different configurations, the Omega fits any production floor: In your shop, in an automated production line, or anywhere in between. • Dissimilar Welding Capabilities. Copper...

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World-Class Battery Welding Solutions-3

Take a Closer Look at the Omega’s Touchscreen Interface! Save any weld, load any saved weld, or clone any saved weld to another Omega welder. The Omega is 100% PLC ready and can significantly boost your production levels. For added versatility, choose three different weld modes: Weld head, Pulse arc, or Tack. The waveform graphically displays the current weld’s characteristics. The Omega does the thinking for you! Simply choose materials and thicknesses and enjoy perfect welds. The touchscreen display and proprietary software interface makes it easy to make quick adjustments. You can fine tune...

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World-Class Battery Welding Solutions-4

Now available in Four Models: • 200 • 400 • 600 • 1200 NEW! Advanced CD Fine-Spot Resistance Welders Precise, Repeatable Control Over Every Aspect of Every Weld • Touchscreen, Full-color Interface Software Updates with WiFi Connectivity High-precision Energy Adjustment Built-in Training Videos, Documentation Visual Graph of Weld Waveform Histogram Comparator with Voltage, Current, Power Alarms and Warnings Timestamp Data Feedback Import/Export Weld Data Multiple Languages Save Settings Full Welder Cloning Capabilities Easy-to-Reach Emergency Stop PLC Ready Dual Weld Head Control Roll-spot Welding...

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World-Class Battery Welding Solutions-5

Specifications TABLETOP FOOTPRINT (L X W X H) UNIT WEIGHT INPUT VOLTAGE FREQUENCY RANGE POWER FACTOR (typ.) * AC CURRENT (typ.) POTENTIAL PEAK INPUT ACTUAL AVERAGE CURRENT (welding) SINGLE AND DUAL PULSE PULSE 1 ENERGY ADJUSTMENT PULSE 2 ENERGY ADJUSTMENT WELD PULSE CHARACTERISTICS MIN AND MAX OUTPUT MIN AND MAX PULSE WIDTH RISE TIME (to max voltage) MIN AND MAX PULSE HEIGHT WELDS PER MINUTE BY % OF TOTAL WELD ENERGY (IN DUAL PULSE MODE, MAX ENERGY, PULSE WIDTH AT 100%) 0.10% with both pulses enabled PEAK WELD CURRENT* (BY EXTERNAL CABLING GAUGE NUMBER, AWG. FOUR AND EIGHT AWG IS TYPICAL FOR...

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World-Class Battery Welding Solutions-6

The Sunstone™ Dual Pulse CD Spot Welder Available in Three Models: 200 • 400 • 600 Time Tested and Proven Fine-Spot Welders Dual Pulse Capabilities for Clean, Strong Welds! • Go-to Solution for Battery Pack Manufacturing, Infinitely Adjustable Pulse Width Built for Alkaline, Ni-Cd, NiMH, Lithium, or Other Easy-to-Reach Terminals and Controls Custom Battery Packs, Re-builds, and Tabbing Specialty Metals Digital Energy Display for Precision Welds Single or Dual Pulse Operation Quick Performance: Up to 164 welds per minute Roll Spot Capable PULSE 1 ENERGY ADJUSTMENT (% OF SET-POINT ENERGY) PULSE...

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World-Class Battery Welding Solutions-7

The Sunstone™ WH2 Weld Head Manual or Air Actuated Options A Weld Head with a Proven Reputation for Dependability The Perfect Delivery of Energy Ends Here! • Manual or Pneumatic Actuation Adjustable Weld Head Height from 0-20.3 cm Adjustable Pressure from 1-15 lbs of Weld Force Included Foot Pedal for Easy Operation Accepts 1/4” Electrodes Adjustable Force-Firing Adjustable Up/Down Stroke Velocity Quick Release Height Adjustment Handles Specifications MANUAL WELD FORCE ELECTRODE DIAMETER ELECTRODE DIAMETER UPGRADES ELECTRODE CONFIGURATION ELECTRODE HOLDER TYPE WELD CABLE SIZE/LENGTH FOOT PEDAL...

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World-Class Battery Welding Solutions-8

Call or Text +1-801-658-0015 • www.sunstonewelders.com ©Sunstone Engineering LLC. Sunstone is a trademark of Sunstone Engineering LLC. Product specifications subject to change. Call for details. V202007

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.