Sponsored by Sunstone Engineering

Sunstone’s new Omega PA250i battery welding system can do what different welders wrestle to perform: Connect copper to metal or aluminum. By utilizing a pure copper tab to attach one energy cell to a different, EV producers will notice a big increase in energy cell effectivity.

So why do most EV producers shrink back from copper?

Fixing the Copper Paradox

From our days in highschool chemistry class we discovered that in relation to conductivity, copper is king. No different non-precious metallic accommodates the movement of power like copper. The excessive conductivity of copper tabs improves the efficiency of the ability cell, as a result of the movement of power from the ability cell to the EV’s different programs meets much less resistance. Energy effectivity will get an enormous increase when utilizing copper tabs.

The paradox to copper’s love for power is the problem of attaching it to different metals. Fairly frankly, copper doesn’t play properly with different metals. Reaching a suitable weld is troublesome, which is why many producers flip to blended metallic tabs for the manufacturing course of. Utilizing blended metallic tabs reduces effectivity however speeds the manufacturing course of. Briefly: Producers have been compelled to compromise.

The Omega contains new welding expertise, developed by Sunstone, that clears a path for EV producers to make the most of pure copper or nickel tabs within the manufacturing of energy cells. 

“The Omega opens up new potentialities for EV producers,” says Jonathan Younger, president of Sunstone Engineering. “They’ll benefit from the conductivity advantages of copper or nickel tabs with out affecting manufacturing ranges. With the Omega, they will now develop a considerably extra environment friendly energy cell and produce it simply as simply as every other. Battery efficiency is paramount to the patron expertise, which might differentiate one’s merchandise in a aggressive market.”

Shock and Pleasure within the Lab

Larin Dodgen, who heads up Sunstone’s growth crew, knew the modifications made to the {hardware} and software program would enhance weld outcomes. “Suggestions from our prospects and issues we discovered within the lab was driving our growth efforts in the precise course,” he says. “However the outcomes from our first check exceeded my expectations. A lot in order that I acquired this massive smile on my face. Once I shared the outcomes with the opposite engineers, all of us acquired fairly excited.”

The Omega’s welding expertise is constructed on the muse of Sunstone’s 15 years of growth and manufacturing of battery welding programs. “The Omega’s ratio of profitable welds to failed welds is 15 instances higher,” says Dogen. “Electrode efficiency is infinitely improved over our earlier system. And the total PLC capabilities present extra management with personalized enter and output for prime manufacturing.”

Absolute Digital Management

“The specificity of the Omega is the important thing to why it is ready to consecutively produce optimum welds,” says Younger. “A profitable weld, for any sort of metallic or mixture of metals, is the results of having the ability to modify and tinker with each recognized contributing issue. And now, with the Omega, the expertise is mechanically adjusting the welder primarily based on the supplies concerned to create an optimum welding outcome.”

As with lots of Sunstone’s micro welders, the Omega PA250i is managed by a mounted touchscreen interface. The operator can digitally management all facets of the weld, from energy to waveform to agitation. Particular to the Omega, when the operator enters the sort and thickness of the metals to be welded, the Omega will mechanically set the weld parameters for an optimum weld for that mixture of metallic and thickness.

The Omega’s digital management additionally supplies the operator with the power to avoid wasting welds, after which load and apply these settings to comparable jobs sooner or later. Weld settings may also be cloned from one unit to a different, which saves time in establishing manufacturing processes.

The Benefits of Versatility

One other benefit to the Omega is its versatility. it’s not only a key instrument for the R&D crew. It’s not only a welder for a small or mid-size manufacturing ground. And It’s not only a sensible cog in an automatic manufacturing facility. The Omega PA250i could be configured in three alternative ways to match the wants of the producer.

For analysis and growth, the stylus configuration supplies the lab with 5X optics and pulse arc welding expertise. “R&D people love the Omega for its ‘fly-by-wire’ digital management,” says Younger. “In addition they just like the optics that make evaluating the weld outcomes simpler.”

For small to mid-size manufacturing flooring, a weld held configuration could also be extra appropriate. The operator makes use of the Omega to regulate the weld head with easy foot pedal inputs. “The weld controls could be locked,” says Younger. “So, a manufacturing supervisor can set the weld parameters and know they will’t be adjusted, which might have an effect on manufacturing high quality and consistency.”

And for large-scale, automated manufacturing facility, the Omega PA250i, with its PLC capabilities, connects to a CNC-mounted weld head. The system could be cloned to create extra programs to extend manufacturing volumes. “The Omega is a great welder, production-ready, PLC-capable, and could be an integral a part of any large-scale manufacturing course of,” says Younger.

Turning a Chilly Shoulder to Solder

One other key benefit is the warmth affected zone. For the Omega, as a result of the weld is small, concise, and brief, the world surrounding the weld is minimally affected. For battery cells, the warmth affected zone is necessary to particular person cell efficiency. When a tab or connector is hooked up to cell extreme warmth over a protracted time frame is detrimental to cell efficiency.

Whereas soldering’s warmth affected zone is massive and extended, by way of time, a weld’s is small and brief. If you view a soldered tab by an infrared digital camera, the warmth affected zone turns into fairly clear and pronounced. “An infrared picture dramatically illustrates the benefit of a weld over a soldering,” says Younger. “It’s alarming. You’ll by no means need to solder once more.”

The opposite benefits of welding over soldering is a cleaner work space. Soldering is messy, dearer, and produces poisonous fumes. A weld, alternatively, is clear and extra environment friendly.

Samples Inform No Tales

EV producers can request a pattern from Sunstone to display some great benefits of the Omega battery welding system over different manufacturing processes. “I can speak all day lengthy and spin an awesome story,” says Younger. “But when I put an precise pattern in your palms the story telling turns to factual illustration.”

Requests for a pattern could be made by calling or texting +1-801-658-0015 or visiting www.sunstonewelders.com/Omega-sample.

Sponsored by SunstoneEngineering