Extreme Remote Welding

Micro Welding in Far-Removed or Hard-to-get-to Worksites

Strain gauges can create as much stress as they measure. Designed to record or detect stress or force being applied to bridges, tunnels, wind turbines, or other load-bearing structures, oft times engineers are attaching strain gauges in places far removed from the nearest electrical outlet or in spots that are difficult to access. Moreover, temperature conditions may require gauges to be welded to key components rather than attached using epoxy.

When strain gauges are attached using a fine spot weld, usually less than one millimeter in diameter, remote work areas may not have power for your run-of-the-mill micro welder, like a Sunstone CDSP welder. Or, the work area may be difficult to access, such as at the top of a wind turbine or communications tower.

In those instances, engineers are turning to the Sunstone Scout, a battery-powered, micro welder. The Scout packs 100 Ws of power, more than enough energy to attach a strain gauge or work with other electronic devices. With a single charge the Scout will deliver up to 2,000 welds and recharges in six hours.

“The Scout serves a unique niche in civil engineering,” says Thane Kennedy, product manager at Sunstone. “For those times when you need a tiny weld in a tight spot, the Scout is the perfect solution. In Australia, for example, energy companies are taking the Scout into the bush. It’s small enough to throw into the back of truck, helicopter, or bush plane.”

Weighing in at 11.4 kg, the Scout can be attached to a utility belt or safety point using it’s unique, center handle. Operators will also appreciate the Scout’s storage compartment, which keeps hand attachments and cables safely tucked away when not in use.
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To promote the Scout’s remote appeal, Sunstone produced an entertaining video that turned heads for its creativity and cinematography.