Welding Technology Spotlight: Sunstone Omega PA250i
Sunstone’s new battery welding system is a cardinal welder; a welder of all welders; a welder that all welders aspire to be. The Omega PA250i is packed with versatility and holds a black belt in the martial arts of welding.
Let’s start first with versatility.
The Omega is not a one-size-fits all answer. The engineers at Sunstone recognized the need for the welder to transform readily to meet the needs of any given organization, or any given department within an organization. That’s why the Omega is available in three different configurations, being able to meet the needs of many different types of shops.
For the R&D shop, the Omega provides advanced pulse-arc technology, 5X optics and Sunstone’s lauded digital welding interface. The pulse-arc and optics duo allows any lab to test myriad configurations to find the absolute best welding schedule.
For mid-size production facilities, the Omega can be paired with a manually actuated or pneumatic weld head that can keep up with production demands. Of course, the weld head is controlled by Sunstone’s digital welding technology, so operators can expect excellent weld results.
For production facilities that are totally automated, the Omega can be paired with a CNC table using the Janome Cartesian Robot. While the Janome takes care of where the weld is placed, the Omega controls the delivery of the weld.
The Omega’s versatility makes it a good fit for any type of shop. Or, for larger organizations, the Omega can find a home with the R&D team or on the production floor.
Let’s Talk about Features
The Omega’s welding performance is made possible by Sunstone’s digital welding interface. A 10-inch color touchscreen allows the operator to control every aspect of the weld, from power to agitation to weld length.
After the operator selects the desired attributes, the weld is displayed graphically as a waveform. The operator can see in real time how the weld is affected when different settings are selected. The digital control of the weld is what allows the operator to find, produce, and replicate the perfect weld.
Weld schedules can be saved and used for another time. Schedules can also be cloned to another Omega welder in a matter of seconds. The Omega is 100% PLC ready. One or many Omega welders can be controlled from one source, which is perfect for large, automated production lines.
One feature some operators will appreciate is the Omega’s on-board automation. Simply select the type and thickness of the metals you’re working with and the Omega will suggest the right combination of settings to deliver the perfect weld.
Bread and Butter Features
The Omega can deliver up to 250 Ws of energy. The operator can dial in the power down to 1/100th of a Ws. Weld materials between .003-.030 inches (.075-.75mm) in thickness.
The operator can store up to 127 different welds with the ability to lock out other operators from making changes to saved welds or the current weld. On a production floor, when operators change from shift to shift, locking the current weld settings provides the company with quality control.
Sunstone makes the claim that with the Omega’s digital welding technology any organization can turn to pure copper tabs to boost battery efficiency. “Copper is tricky,” says Thane Kennedy, Product Manager at Sunstone Engineering LLC. “When faced with the challenges of creating battery packs, manufacturers turn to nickel or clad to connect each individual can, because they are relatively easier to weld. The increase in production efficiency is offset by a subsequent degradation in battery efficiency. With the Omega, manufacturers aren’t forced to choose one over the other. They can now weld copper tabs just as easily as any other type of tab and enjoy increased battery efficiency.”
As a serious piece of welding technology, the Omega can be protected by a perpetual product protection plan called the Sunstone Circle. As long as you remain a member of the Circle via a monthly subscription, the Omega’s warranty never expires.
In the end, the Omega offers a great deal of flexibility tightly controlled by advanced welding technology.