ADVANCED fine-spot resistance welders
Sunstone’s advanced dual pulse CD welders offer many capabilities including weld monitoring, SPC tools, and a large capacitive touch-screen interface. The touch-screen interface provides easy access to all weld parameters. In addition, you get a visual of the weld waveform graph, weld histograms, alarms, warnings, and even on-screen documents and videos. For automated production settings, the welder has multiple PLC protocols. You can also set up multiple machines in a simplified way thanks to the clone feature. Cloning allows you to copy all your parameters/settings and easily export/import them to other machines.
Capacitive Discharge (CD) resistance welders have many advantages over other welder types. Since CD welders use capacitors to store and release weld energy, your weld energy will be highly repeatable and will not be affected by line voltage fluctuations. You can also achieve quick energy release for welding highly conductive metals such as copper. This quick energy release is concentrated into a small area, generating only a small heat signature or heat affected zone.
Built In Weld Monitoring
Resistance welding can be easily controlled and monitored, with the CDDCP-A, to ensure and guarantee high-quality welding results. Several factors can be controlled to accomplish proper weld monitoring. One of the most critical factors in weld monitoring is Current Monitoring. Measuring the peak current ensures that each weld is discharged to the desired amount. The Sunstone CDDP-A measures and displays the actual peak current of the previous welds. A histogram can be displayed to view a range of your past welds. There are three types of monitoring; current, voltage, and power.
Current monitoring will deliver the programmed current regardless of workpiece resistance changes. It can compensate for slight variations in part thickness without affecting weld quality. It is best suited for welding flat parts where the part-to-part and electrode-to-part contact is controlled and consistent.
Voltage monitoring controls the voltage across the workpiece during welding. It helps to compensate for part misplacement and force problems. It automatically reduces weld splash, which is often associated with non-flat parts and wire welds. Voltage monitoring is ideal for welding round parts.
Power monitoring precisely varies the weld current and voltage to supply consistent weld energy to the parts. It is especially useful for breaking through surface oxides and plating. It should be considered for automated applications where part or electrode surface conditions can vary over time. Power monitoring extends electrode life in automated applications.
What is Dual Pulse?
What is a Dual Pulse Welder and Why is it important? A Dual Pulse Welding system uses two pulses to provide the best possible weld results.
In resistance welding, getting the electrodes seated in the right place and having good contact is vital to direct the heat to the desired area. In a resistance weld, the heat is generated due to the resistance in the gap between the parts that you are trying to weld.
If the electrodes are not adequately seated with good contact, welding can occur between the electrodes and the workpiece, rather than the desired weld location. This condition causes electrodes to stick and become embedded in the workpieces. This causes excessive wear on the electrodes and higher costs as a result.
With a dual pulse system, the first pulse is a small cleaning or seating pulse which is sent before the second (or welding pulse). The first pulse eliminates any possible contamination and electrode contact problems.
A dual pulse system will reduce weld splash, improve weld quality and consistency, reduce costs, and aid in welding plated materials. This cleaning pulse can easily be turned off if a single pulse is desired.
Roll Spot – Continuous Welding Mode
Roll Spot feature allows the users to perform a continuous string of welds for any prolonged period. As long as the trigger is activated, the welding system will continue to send a succession of welds. Roll spot allows you to roll across mesh, screen, or foil and perform welds at a set interval. This is similar to a sewing machine welding in a stitch pattern. Roll spot welding requires the use of a roller electrode and handpiece or weld head. Through the user interface, welds per second can be adjusted to get the right frequency required. Two variables will affect the distance between welds as the electrode is rolled across the surface. The first variable is the welds per second setting and the second is the speed at which the electrode is rolled across the weld area. Roll spot functionality will give you the ability to quickly and easily complete seam welds on a mesh, screen, or foil. This can be used for several applications including filters, screens, baskets, tube, and many other filtration applications.
Set Pulse Limits
Process control can be accomplished by measuring and setting monitoring limits for the peak current, power, and voltage. These limits can be adjusted for each individual application. These limits represent the range of acceptable welding strength. The CDDP-A will monitor and detect whether the peak current is within range or out of range. It can then be programmed to stop welding and send an alarm, or flag that particular weld and continue. This weld monitoring ensures that each weld is within parameters that guarantee successful welds in fully automated systems. These user set control limits help to prevent and detect weak welds.
Fast Capacitive Discharge Rise Time
The Capacitive Discharge Dual Pulse Advanced (or CDDP-A) uses energy that comes from plugging your system into the wall. That energy is stored in capacitors that are inside the CDDP-A system. These capacitors store the energy until a weld is triggered. Through the touch screen interface, the user adjusts the amount of energy that is desired in Watt Seconds. When a weld is triggered, the CDDP-A quickly discharges the stored energy from the capacitors and achieves a fast rise time. This ability to precisely control and discharge energy is the core of how the CDDP-A can achieve micro-welding results with precision and repeatability.
The Sunstone CDDP-A includes the use of a histogram to visualize the quality and constancy of welds. These histograms are used to view and analyze continuous data. Each weld in a series of welds in charted on the histogram to show the long term trends affecting the welding quality. These essential quality control features are designed and built for production and automated welding systems. The histogram can be viewed for the previous welds, and a large number of welds can be displayed to ensure continual high-quality welding performance.
Simple Touch Screen
The Sunstone CDDP-A includes a high definition full touch screen display. This touch screen interface is used to change all settings. The screen is also used to display monitoring information and as well as training videos and material. The Touch screen allows you to see everything that you need quickly and efficiently. The user interface is simple to understand and easy to adjust the necessary settings. No buttons, dials, or old readouts. The CDDP-A uses the latest touch screen and display technology to help you be more productive.
Easy Setup & Machine Cloning
Setting up the CDDP-A is simple, with detailed instructions and videos to guide you through the process. With several different configurations that will fit your needs and applications. Stop wasting your time setting up complicated machines, spending hours reading complicated manuals to perform a few simple welds. Setting up several devices with the same settings? The Sunstone CDDP-A Includes the ability to clone the settings from one machine and load them on another unit. Cloning allows you to copy all parameters/settings and easily export/ import them to another unit. This makes setting up multiple machines simple and easy.
Battery Welding with the CDDP-A
One of the typical applications for the CDDP-A is welding tabs on battery cells. These battery cells may include cylindrical cells, prismatic, pouch, and ultracapacitors.
CD welding is commonly used to weld lithium battery cells to make custom battery packs. These battery pack can be huge with thousands of welds each. The CDDP-A can be used in conjunction with a CNC robot to complete automated welds. These automated welds can drastically improve the quality and quantity of mass-producing battery packs.
The CDDP-A Includes many features that aid in battery pack manufacturing, including welding monitoring, PLC controls, remote schedule adjustment, and numerous triggering options. Learn more about how to increase your efficiency and quality by using the CDDP-A to weld batteries.
Weld Head Control System Built-In
The CDDP-A, when paired with a pneumatic head, can control the weld head and allow for a single foot pedal operation. The user can control the squeeze time, the weld settings, and the release.
This allows for precise weld timing to be controlled every time with consistency, The user can orient the parts to be welded under the electrode either through a fixture or by hand. Then simply press a single foot pedal. This will initiate the weld head and apply the set force to the weld joint.
The CDDP-A will then trigger the weld with its set timing or trigger control from the weld head. Then the weld head can be programmed to remain in a squeeze as the parts cools. Later the weld head pressure will be released. This feature allows for consistency no matter who is using the machine. This will provide more consistent and precise welding results.
Compatible with Both Manual & Pneumatic Weld Heads
The CDDP-A can be paired with several various attachments. These attachments include both weld heads and handheld weld attachments. These welding attachments help to deliver the energy from the power supply to the workpiece. Weldheads vary in configuration and drive systems. Parallel weld attachment or Dual Probe has two electrodes on one side, and make a side by side weld, such as welding a tab to a battery. An opposed or single probe welding attachment applies pressure to both sides of a weld and performs a pinch weld, such as welding two pieces of plate together. An opposed weld flows energy through the whole part. Weld heads can be controlled with both manual or foot driven operations, or by using a pneumatic drive unit to apply the pressure to the weld site.
including inputs such as Primary and Secondary Trigger, Lockout, Remote
Many automated applications require the use of PLC Communication and tools. The CDDP-A Includes many PLC functionality that allows both inputs and outputs from computerized systems. Inputs available include primary and secondary triggering, lockout functionality, and remote schedule select. Outputs that the unit sends are weld ready, weld good, weld no good, any warning, any alarm, and also emergency stop. This PLC Functionality provides for easy connections and communication with automated systems. The CDDP-A is automation-ready and can be added into a new or existing production line with ease.
Emergency Stop Compatible
Each CDDP-A welding system includes emergency stop functionality. This allows the user to set up an emergency stop that will cut the power to the welding system in case of an accident. This will prevent the machine from releasing any energy in case of an emergency situation. This safety feature is enabled on every unit and must be closed using the emergency stop bypass plug. This essential feature helps in both automated and manual welding operations and can be used in conjunction with many other safety systems to ensure the safety of the operator and the machine.
Built-in training videos and PDF’s
Having the machine set up correctly and knowing how to use it to perform welding functions is key to the success of any welding system. Here at Sunstone, We strive to make this as easy as possible, by providing detailed setup instructions, and operation training. This training can easily be accessed right from the machine itself. Built into every welding system is a library of training materials. These materials include detailed videos of settings adjustments, setup instructions, application setup, and support. This gives you the tools to be successful right from the start, right where you need them. This allows you to be operating sooner, with less downtime learning and training of the operation and set up of the machine. As always, we are here to help in your process. If your question is not answered, we are available to train and support anytime. Knowing how to use your machine is key to your success and ours, we are your partner in finding a welding solution.
Save and Load Preset Weld Schedules
Easily save the perfect settings for that application into the user interface. The Save functionality allows you to keep all of your detailed settings by only one press. Once you have identified the perfect parameters simply press the save button, name the application for easy identification, and even add notes to remember critical details of your setup or operation. When you are ready to use those settings again, simply press the load key, and find the saved settings. This will instantly load all of your settings exactly as you had them, and allow you to continue just as you left off. Save as many applications as you would like, as the save memory will accommodate as many saved settings as you like. This saves you time and effort remembering or writing down and re-entering settings each time you change applications.
Lock Out Functionality
Once a unit has been set to the proper settings and is in operations, the CDDP-A includes lockout functionality. This allows users the ability to lock the machine to any changes. This lockout enables the unit to function and perform welds, use monitoring, and trigger welds. It merely locks out any changes to the settings. This lockout can be turned off and on with a simple passcode that allows and disallows any changes. Lockout is essential in production environments where numerous users use the machine. This allows a single user to set up and tune the welds in, then apply the lockout. Once production has started, each weld will be consistent and unchanged.
Features and Applications:
- Touch-screen interface
- Set current or voltage
- Visual graph of weld waveform
- Statistical process controls
- Alarms and warnings
- Timestamp data feedback
- Full welder cloning
- Emergency Stop
- Roll-Spot Welding
- High-Precision Energy Adjustment
- Lock-Out Mode
- PLC Ready
- Import/Export weld data
- Software updates
- Multiple languages
- Save settings
- Wi-Fi connectivity
- On-screen PDFs and videos
“I recently bought your CDDP-A 600 welder with WH2 weld head… one word to describe it: AMAZING! Best welder system I’ve seen so far for 18650 tab welding.
Thank you Sunstone!”
– As seen in the comments of our CDDP-A Setup Video on YouTube