Omega PA250i Welding System

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.

OMEGA PA250I USER MANUAL

ORION PA250I DATA SHEET

		COPPER Tabs	NICKEL Tabs	The COPPER Difference
Boost Efficiency With copper tabs, power cell efficiency significantly improves. And when the customer experience is all about battery performance, copper is king!	Conductivity	1.18 x 10⁷σ	5.96 x 10 ⁷σ	5x More
	Resistivity	1.68 x 10^-8ρ	8.50 x 10^-8ρ	80% Less
Save Money Copper tabs will connect your power cells more efficiently and do it for more than half the price compared to some nickel.	Price as of OCT 2020	USD $3.09/lbs	USD $7.16/lbs	57% Savings
Weld Confidently With copper, attach a thicker tab for a larger spot size and improved peel strength. Plus, the heat affected zone is small, quick and wont damage the power cells internal components.	Nugget Area	5.06mm²	0.29mm²	17x Larger
	Nugget Diameter	2.54mm	0.61mm	4x Larger
	Peel Strength	10kg/22lbs	6kg/13lbs	66% Stronger
	Thickness	0.010 - 0.020"	0.005 - 0.010"	2x Thicker

Sunstones Omega PA250i Copper Battery Tab Welder Provides:

Feature	Benefit
Dissimilar Welding Capabilities	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
Digital Control	Adjust and control all energy attributes with color touch screen
Visual Waveform Graphs	View energy waveforms and histograms
PLC-Ready	With 5 outputs/2 inputs easily integrates into your production process
CNC Compatibility	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
Lock-Out Mode	Prevent changes to production settings
Alarms and Warnings	Avoid time-consuming errors or potentially hazardous conditions
Built-in Training	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

Sunstones 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.