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The Case for Copper
One of the biggest challenges when welding EV batteries is finding a welder capable of welding highly conductive metals such as copper and aluminum. Inside a lithium-ion battery are various copper and/or aluminum components that carry the electrical current (such as buss bars). These components are commonly joined to either similar or dissimilar materials to facilitate the electric current. If the joint is not made properly, there is a potential for voltage drops due to the resistance between the two pieces. The Omega PA250i welder is capable of overcoming some of these challenges, thus opening new doors in the world of EV battery welding, specifically by being able to weld copper tabs to battery cans.
Copper to steel, copper to aluminum, nickel to steel—ideal for battery welding!
3 Available Configurations
1) Stylus only 2) Weld head 3) CNC table
250 Ws Max Energy
The most powerful Sunstone pulse arc micro welder yet!
Weld materials 0.003-.030” (0.075-0.75mm) in thickness
Perfect for attaching copper tabs to power cells
Adjust and control all energy attributes with color touch screen
Visual Waveform Graphs
View energy waveforms and histograms
With 5 outputs/2 inputs easily integrates into your production process
Attaches to any CNC table, like the Janome Cartesian Robot, for maximum production levels
127 Remote Schedules
Saves time with access to saved welds
Import/Export Saved Welds
Easily transfer settings to other units
Prevent changes to production settings
Alarms and Warnings
Avoid time-consuming errors or potentially hazardous conditions
How-to videos always at your fingertips
WiFi Software Upgrades
On-board software is easily maintained
Overview and Applications
The Omega PA250i Copper Tab Battery Welder is capable of welding highly conductive metals such as copper and aluminum. It also comes in a CNC version that is capable of performing all the same tasks with the assistance of a CNC table.
This system brags an all new design and performance. This latest update takes all of the great features from our previous model and adds to it a new motorized weld head adding greater control, precision, and uniformity to every weld. Manufacturers can produce lighter, more compact battery packs without compromising power or capacity.
Features and Benefits of the Sunstone Omega PA250i Copper Battery Tab Welder:
Solderless Connections– The metals are fused together at the weld spot for a continuous connection and no voltage drops.
Clean Weld Spots– During the welding process, surface contaminants are burned off, allowing for strong, clean welds.
Weld Dissimilar Metals– Sunstone Spot Welders can weld any combination of metals, such as Copper to Aluminum.
Small Heat Affected Zone– The heat-affected zone (HAZ) is very small and very localized to ensure no degradation to the battery. The 250i provides enough energy to make the weld without affecting the integrity of the cell.
More About the Omega PA250i Copper Tab Battery Welder System
The Omega PA250i is the perfect copper battery tab welder. The Omega PA250i has a new design to give superior performance. This newest update takes all of the great features from our previous EV copper tab battery welder, and adds to it a new motorized weld head for greater control, precision, and uniformity to every weld. The power supply has also been upgraded to offer superior control and fine-tunabilty to guarantee the perfect weld can be achieved. Manufacturers can produce lighter, more compact, and more efficient battery packs without compromising power or capacity.
The Omega PA250i in Action
Customer Spotlight on Vantage Power
The Omega PA250i CNC Version
Sunstone’s Omega PA250i copper battery tab welder also comes in a CNC version that is capable of performing all the same tasks with the assistance of a CNC table. Watch the below video to see it in action.