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Summary of Contents for SUNSTONE MICRO E
- Page 1 MICRO ™ Weld Head Users Guide with Advanced Electromagnetic Linear Motion Version 20210701 • Part #1218...
- Page 2 INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY OR PUNITIVE DAMAGES, OF ANY NATURE WHAT- SOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGINEERING LLC PROD- UCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGI-...
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Page 3: Table Of Contents
e Micro Welder Experts Contents Chapter 1: Weld Head and Resistance Welding Overview ......1 What is Resistance Welding? ................... 2 Contact Resistance ..................... 2 Bulk Resistance ......................3 Capacitive Discharge (CD) ..................3 Direct Current (DC) ....................... 4 Chapter 2: How to Setup the Weld Head ..............6 Initial Set-up ........................ - Page 4 with Advanced Electromagnetic Linear Motion...
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Page 5: Chapter 1: Weld Head And Resistance Welding Overview
With minimal set-up and adjustment, you will be on your way to performing consistent, repeatable micro welds. Your Sunstone Micro E Weld Head can be adjusted to forces from 5g to 2000g for use on a wide range of ap- plications. -
Page 6: What Is Resistance Welding
• Rotary Knob Height Adjustment • Multiple electrode configuration possibilities: opposed, parallel gap, fixed gap, and thermocompression WELD HEAD APPLICATIONS The Sunstone Micro E Weld Head is an efficient tool for the fol- lowing applications: • Cross wires • Thermocouples •... -
Page 7: Bulk Resistance
e Micro Welder Experts and create the “Contact Resistance”. During the first few mil- liseconds of weld formation these bridges melt, allowing other bridges to come into contact to continue the melting process. Bulk Resistance Once all the bridges have fused, the contact resistance nears zero. -
Page 8: Direct Current (Dc)
MICRO USERS GUIDE ™ Direct Current (DC) • A DC welder delivers continuous peak current for set periods of time. See Figure 4.1. Peak current is lower than CD welds, but more sustainable. • The current is more consistent throughout the weld process. - Page 9 e Micro Welder Experts pressive force to create fusion with the substrate material. Thermocompression welding can be used to attach magnet wire without pre-stripping the coating from the wire. DC welding power supplies are ideal for thermocompression welds due to the lower peak currents (help to maintain the tip life) and controllable weld length.
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Page 10: Chapter 2: How To Setup The Weld Head
USERS GUIDE ™ Chapter 2: How to Setup the Micro E Weld Head Carefully follow these instructions to prepare the Sunstone Micro E weld head for operation: Initial Set-up • Remove the weld head from its packaging and place the assembly on a level surface. The base of the unit can be bolted to the table using optional mounting brackets for increased stability. - Page 11 e Micro Welder Experts HEIGHT ADJUSTMENT Reference Figure 6.1 and follow these instructions to adjust the height of the weld head from its base. • Loosen the two T-handle knobs (A) on the right side of the unit toward the back. •...
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Page 12: Electrode Holder Setup
MICRO USERS GUIDE ™ • Attach the RED weld cable (coming from the bottom of the weld head) to the welding power supply (+) terminal. Use the included ¼-20 x 5/8” socket cap screw with lock washer and hex nut. Make sure the screw is tight for best weld results. -
Page 13: 1/8" Rectangular Electrode Installation Procedure (Fixed Gap)
e Micro Welder Experts • Insert the electrode between the clamp plates and hold at desired height. CORRECT • Turn the thumbscrew (C) clockwise to tighten the elec- trode in place. A pair of pliers can be used to ensure tightness if desired. -
Page 14: 1/8" Rectangular Electrode Installation Procedure (Adjustable Gap)
MICRO USERS GUIDE ™ • Insert the electrode between the clamp plates and hold at desired height. • Turn the thumbscrew clockwise to tighten the electrode in place. • Tighten the screws on the front of the electrode holder to clamp against the electrode. Step 3: Adjust Weld Head height •... -
Page 15: 1/8" Opposed Electrodes Installation Procedure
e Micro Welder Experts • Lock the electrodes in place by tightening the screws on the front of the electrode holder (check to make sure the position does not change while tightening. • Remove the block and position the weld head such that the tips of the electrode hover between 1/8” and ¾”... -
Page 16: Opposed (Direct Weld)
Electrodes come in Glidcop, molybdenum, and tungsten, with a variety of tip shapes. Step (Adjustable Gap) In the Step configuration, the Micro E places electrodes on both materials, but from the same side. See Figure 13.2. Welding in the Step configuration can be challenging; maintaining proper pressure at each electrode is dif- ficult due to possibly uneven surfaces. -
Page 17: Series (Adjustable Gap/Fixed Gap)
Thermocompression When the Micro E is configured for thermocompression welding, the current does not pass through the materi- als being welded. Rather, the current passes through the electrode tip. See Figure 14.1. Thermocompression electrodes are typically used to weld magnet wires or other coated wires. They typically come with an 1/8”... -
Page 18: Ergonomics
MICRO USERS GUIDE ™ ELECTRODE TIP RATINGS Different tip sizes can handle different amounts of force. As a general rule, use the following as a guide: • .01” x .01” – 40-1000 grams • .015” x .025” – 125-1500 grams •... - Page 19 e Micro Welder Experts Main Arm Angle Secondary Arm Angle Scope Focus Scope Height ~36° Figure 15.1. Use these four adjustment points to achieve a comfortable viewing posture. Step 3: Focus • Rotate the focus knob (3) until the work piece comes into focus. Some additional adjustment of the height and arm angles may be necessary to achieve ideal focus.
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Page 20: Chapter 3: How To Operate The Weld Head
The operator assumes all liability. Software Interface The Sunstone Micro E weld head interfaces with (is controlled by) an accompanying welding power supply. All communication between the weld head and the welding power supply takes place using the included 6’ RJ12 COMM cable. -
Page 21: How To Weld
e Micro Welder Experts How to Weld Once setup is complete, the unit is ready to commence welding. The modes and parameters can all be adjust- ed from the welding power supply interface. CHOOSE A MODE Direct Control Mode: The operator controls position of the servo using an analog foot pedal. Auto Control Mode: Servo position and movement is controlled automatically by the welding power supply. -
Page 22: Force
2. The distance between the hover point and the approach point. 3. The weld point to the hover point. Note: The Sunstone Micro E weld head travels at slightly lower speeds between the hover point and the ap- proach point versus home and hover or weld point and hover. -
Page 23: Tips And Recommendations For Successful Welds
e Micro Welder Experts To perform a test run: • Ensure the Weld On/Off button is in the off state on the welding power supply. • Verify that the microscope is set up properly to view the weld area. • Place the work piece below the electrodes and practice lining up the electrodes with the desired weld location. - Page 24 MICRO USERS GUIDE ™ Weld Length Some applications require longer weld times than others to achieve good welds. Keep in mind that the longer the weld lasts, the larger the heat affected zone will become. Weld length plays an important role in Thermo- compression welding because the electrode tip must remain heated long enough for the coating and wire to melt.
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Page 25: Chapter 4: How To Maintain The Weld Head
• Turn off the Micro E weld head. Use the power switch on the side of the unit. • Place a setup block beneath the electrodes (the top of the block should be about a ½” away from the electrode tips. -
Page 26: Weld Head Maintenance
Environment For long life and good performance, it is important to try to keep the Micro E weld head in a clean environment, free of dust, moisture, and debris. When moving the weld head, make sure no cables get pinched and make sure the work surface is sturdy. -
Page 27: Weld Head Specifications
e Micro Welder Experts WELD HEAD SPECIFICATIONS KEY UNIT SPECIFICATIONS 56x10.8x45.7 cm w/ MICROSCOPE TABLETOP FOOTPRINT (L X W X H) 14x10.8x45.7 cm w/o MICROSCOPE 10.1 kg w/ MICROSCOPE UNIT WEIGHT 8.9 kg w/o MICROSCOPE ELECTRODE STROKE (TRAVEL DISTANCE) DISTANCE) 25 mm FORCE RANGE 30-200 g... - Page 28 MICRO USERS GUIDE ™ 24 • Questions? Call or Text +1 801-658-0015...
- Page 29 e Micro Welder Experts Questions? Call or Text +1 801-658-0015 • 25...
- Page 30 ©2020 Sunstone Engineering LLC. Sunstone and Sunstone Circle are trademarks of Sunstone Engineering LLC. Conditions and restrictions apply. Ask for details or visit www.suntonewelders.com/sunstonecircle for complete terms of service. Sunstone Engineering LLC reserves the right to change, alter, modify, or cancel this program at any time.
- Page 31 Expedited Customer More Valuable Upgrades Shipping Service Member Benefits! When your welder is Should your Sunstone At Sunstone every You’ll receive snazzy powered by the latest welder ever need repair, customer is a VIP, but when Sunstone swag, a software improvements we’ll cover the shipping...
- Page 32 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 wwww.sunstonewelders.com PART #1218 ©2021 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Micro are trademarks of Sunstone Engineering LLC. 20210701 • 28 • Questions? Call or Text +1 801-658-0015...
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