SUNSTONE MICRO E User manual
Weld Head Users Guide
with Advanced Electromagnetic Linear Motion
Version 20210701 • Part #1218
MICRO™
ii • Questions? Call or Text +1 801-658-0015
USERS GUIDE
MICRO™
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
ISSUE DATE APPROVAL NOTES
1 DW ORIGINAL
Limitation of Liability
IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING
LLC, ITS DISTRIBUTORS, OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT,
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-
NEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE
ENGINEERING LLC PRODUCT, OR LOSS OF USE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY
THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING LLC PRODUCT,
EVEN IF SUNSTONE ENGINEERING LLC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
WITHOUT LIMITING THE FOREGOING, YOU UNDERSTAND AND AGREE THAT SUNSTONE ENGINEERING
LLC HAS NO LIABILITY FOR ANY DAMAGE OR DESTRUCTION TO ANY PROPERTY. NOTWITHSTANDING
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TATION, ALL DAMAGES REFERENCED HEREIN AND ALL DIRECT OR GENERAL DAMAGES IN CONTRACT,
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OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.
THE LIMITATIONS OF LIABILITY SET FORTH ABOVE SHALL APPLY TO THE MAXIMUM EXTENT PERMITTED
UNDER APPLICABLE LAW.
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Contents
Chapter 1: Weld Head and Resistance Welding Overview.............................. 1
What is Resistance Welding? ...................................................................................
Contact Resistance .....................................................................................................
Bulk Resistance ............................................................................................................. 3
Capacitive Discharge (CD)......................................................................................... 3
Direct Current (DC)....................................................................................................... 4
Chapter 2: How to Setup the Weld Head ................................................................. 6
Initial Set-up.................................................................................................................... 6
Electrode Holder Setup.............................................................................................. 8
1/8” Round Electrode Installation Procedure..................................................... 8
1/8” Rectangular Electrode Installation Procedure (Fixed Gap) .................. 9
1/8” Rectangular Electrode Installation Procedure (Adjustable Gap) ....10
1/8” Opposed Electrodes Installation Procedure...........................................11
Opposed (Direct Weld)..............................................................................................
Step (Adjustable Gap)................................................................................................
Series (Adjustable Gap/Fixed Gap).......................................................................13
Thermocompression.................................................................................................13
Ergonomics...................................................................................................................14
Adjusting the Scope ..................................................................................................14
Chapter 3: How to Operate the Weld Head...........................................................16
Software Interface .....................................................................................................16
Compatible Welding Power Supplies..................................................................16
Verify All Cable Connections..................................................................................16
How to Weld..................................................................................................................17
Position...........................................................................................................................17
Force................................................................................................................................18
Speed..............................................................................................................................18
Timing .............................................................................................................................18
Displacement ...............................................................................................................18
Practice First. Weld Second....................................................................................18
Tips and Recommendations for Successful Welds.......................................19
Chapter 4: How to Maintain the Weld Head..........................................................
Electrode Maintenance ............................................................................................
Weld Head Maintenance..........................................................................................
.......................................................................................
with Advanced Electromagnetic Linear Motion
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Chapter 1: Weld Head and Resistance Welding Overview
What’s in the Box?
• Sunstone Micro E weld head with attached microscope
• 48VDC desktop power supply
•
• Pre-attached 10AWG Weld Cables (Red and Black)
•
• Accessories:
• Scope Eyepieces/cover
• Analog Foot Pedal
• Hex Keys
• Phillips Screwdriver
WELD HEAD FEATURES
With minimal set-up and adjustment, you will be on your way to performing consistent, repeatable micro welds.
-
plications. Some features include:
•
•
• Positional accuracy of 1 micron
• 1” stroke
• PLC compatible
• Automatable
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Figure 2.1. Surface roughness limits surface-to-
surface contact. More contact points result in a
lower contact resistance.
• Removable Ceramic weld base plate
• Rotary Knob Height Adjustment
•
WELD HEAD APPLICATIONS
-
lowing applications:
• Cross wires
• Thermocouples
• Thermocompression bonding
• Strain gauges
• Electronic components
• Magnet wire
• Foil welds
• Research and development
What is Resistance Welding?
Resistive spot welding relies on metal resistivity to heat and
fuse metal. To begin, a large current is passed through the work
piece metal. Energy is dissipated in the form of heat due to the
metal’s resistance to the current. This resultant heat melts the
weld materials, fusing them together. There are two phases to
the melting process. The welder must overcome both the “Con-
tact Resistance” and the “Bulk Resistance” of the material.
Contact Resistance
On the micro scale, surfaces of materials are rough and un-
When two surfaces are pressed together, contact is only made
in a limited number of locations—where the peaks meet the
peaks—instead of the across the entire surface. These contact
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POWER
TIME
Figure 3.1. Sample capacitor discharge curve.
-
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. At this point the second phase of the melting process be-
in weld formation. The “Bulk Resistance” is the inherent resis-
tive nature of the material and varies depending on the type of
material. For most materials, as conductivity increases, resistiv-
ity decreases. Conductive metals such as copper require much
larger amounts of energy to form a weld compared to more
resistive materials such as steel.
ENERGY GENERATION
For any resistive spot welds to take place, electrical current
must be passed through the resistive material to create heat.
Current can be generated using a variety of welding power sup-
plies. Commonly used types of welding power supplies include
Capacitive Discharge (CD), Direct Current (DC), High Frequency
Inverter (HF), and Alternating Current (AC). Choosing the cor-
rect welding power supply for a given application can be an
important step to achieving quality weld results.
CD VS DC VS HF VS AC
Capacitive Discharge (CD).
• A CD welder uses capacitors to store DC energy for
quick release. See Figure 3.1.
•
zones.
• Repeatable energy release independent of line voltage
•
• High initial peak current, but not sustainable for long
periods of time.
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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.
• Repeatable energy release independent of line voltage
• Ideal for very small/thin applications.
• Ideal for thermocompression welds.
High Frequency (HF)
• A High Frequency welder’s discharge is similar to a DC
• Higher available energy than DC.
• Thicker materials can be welded than DC.
• 3-phase input required.
Alternating Current (AC)
• An Alternating Current welder uses transformers to
control the weld current. See Figure 4.3.
• Capable of continuous weld discharge.
•
•
• Can often weld thicker materials than CD.
What is Thermocompression Welding?
Thermocompression welds utilize the resistive nature of the
electrode material to generate the heat for fusion instead of
relying on the resistive nature of the materials being welded.
Thermocompression electrodes (generally made of tungsten)
are specially designed to be fused at the very tip. As current is
passed through the resistive tip of the electrode, heat is gen-
erated. Constant contact between the tip and material being
welded must be maintained with the correct amount of com-
POWER
TIME
Figure 4.1. Sample DC discharge curve.
POWER
TIME
Figure 4.2. Sample HF discharge curve.
POWER
TIME
0
Figure 4.3. Sample AC discharge curve.
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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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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.
• Lift the microscope assembly up and away from the base and then carefully review the following
sections for proper adjustment.
Figure 6.1. To adjust the height, loosen the two T-handle
knobs (A) then turn the large circular knob (B) to move the
weld head up or down. Tighten the T-handle knobs (A)
when the desired height is achieved.
A
B
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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.
• Turn the large circular knob (B) at the back of the unit counterclockwise to raise the unit or clockwise to
lower the unit.
• Once the desired height is achieved, re-tighten the two T-handle knobs (A).
CABLE CONNECTIONS
•
• See Figure 7.1. Connect the power cord (C) to the desktop power supply (D).
• Plug the Barrel Jack Connector (E) of the desktop power supply into the left side panel connector
• Plug the power cord into a wall outlet.
•
head, as shown in Figure 7.3. Plug the other end into the back of your welding power supply in the loca-
tion labeled “Accessory”.
Figure 7.1. Connect the included power cord (C) to the desktop power supply (D) and to a wall outlet. Connect the Barrel Jack
Connector (E) to the power supply port on the left side of the weld head labeled “48VDC 2.5A” (F) as shown in Figure 7.2.
C
D
E
Figure 7.2. Connect the Barrel Jack
connector (E) to the power supply
port on the left side of the weld
head labeled “48VDC 2.5A” (E).
FFigure 7.3. Connect the weld head to
the welder using the RJ12 cable (G).
G
H
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• Attach the RED weld cable (coming from the bottom of
the weld head) to the welding power supply (+) terminal.
lock washer and hex nut. Make sure the screw is tight
for best weld results. See (D) in Figure 8.1.
• Attach the BLACK weld cable (coming from the bottom
of the weld head) to the welding power supply (-)
screw with lock washer and hex nut. Make sure the
• Connect the foot pedal cable to the back of the welding
power supply as directed in the power supply user’s
guide.
Note: To create a clean workspace, it can be helpful to run the
black and red cables as close together as possible (they can be
taped or strapped together if desired).
Electrode Holder Setup
The Electrode Holder has been designed to be used with sev-
-
justable gap rectangular electrodes, and opposed electrodes.
1/8” Round Electrode Installation (Item #MEL TCB)
Step 1: Position Electrode Clamp Plates
• Loosen the two screws on the front of the electrode
holder (A), as shown in Figure 8.3.
• Rotate and position the brass electrode clamp plates
(B) with the “half moon” shape facing inward.
• Tighten the screws fully.
Step 2: Insert Electrode
• Turn the thumbscrew (C) on the right side of the elec-
trode holder counterclockwise to open the gap enough
for an electrode to slide in between the two clamp
plates. See Figure 8.3.
Figure 8.1.Connect the RED weld cable coming from
the weld head to the positive (+) supply terminal on
the power supply..
Figure 8.2. Connect the BLACK weld cable coming
from the weld head to the negative (-) supply
terminal on the power supply..
Figure 8.3. To install an electrode, loosen front
screws (A), position the brass clamp (B), open the
electrode holder by turning the thumbscrew (C).
Install the electrode and then tighten all screws fully.
A B C
D
E
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• Insert the electrode between the clamp plates and hold
at desired height.
• Turn the thumbscrew (C) clockwise to tighten the elec-
trode in place. A pair of pliers can be used to ensure
tightness if desired.
Note: If using a thermocompression electrode, make sure the
line splitting the two halves of the electrode is pointing front to
back, not side to side. See Figure 9.1.
Step 3: Adjust Weld Head height
• Loosen the two T-handle knobs (A) on the right side of
• Turn the large circular knob (B) at the back of the unit
counterclockwise to raise or clockwise to lower.
• Position the weld head such that the tip of the elec-
trode is between 1/8” and ¾” above the surface of your
work piece (consider pre-measured set-up blocks).
• Once the desired height is achieved, tighten the
T-handle knobs (A).
1/8” Rectangular Electrode Installation Procedure
(Fixed Gap) (Item # MEL BMO)
Step 1: Position Electrode Clamp Plates
• Loosen the two screws on the front of the electrode
holder (A). Reference Figure 8.3.
• Rotate and position the brass electrode clamp plates
(B) with the “half moon” shape facing outward and the
notched portion of the plate facing toward the elec-
trode holder.
• Leave the screws loose.
Step 2: Insert Electrode
• Turn the thumbscrew (C) on the right side of the elec-
trode holder counterclockwise to open the gap enough
for an electrode to slide in between the two clamp
plates. See Figure 8.3.
A
B
Figure 9.2. Loosen the T-handle knobs (A) and large
circular knob (B) to adjust the height of the weld head
after you’ve installed an electrode. Tighten the knobs
when nished.
Figure 9.1. When using a thermocompression
electrode, make sure the line splitting the halves of
the electrode is pointing front to back, not side to
side.
CORRECT
INCORRECT
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• 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
• Loosen the two T-Handle knobs on the right side of the unit. Reference Figure 9.1.
• Turn the large circular knob at the back of the unit counterclockwise to raise or clockwise to lower.
• Position the weld head such that the tip of the electrode is between 1/8” and ¾” above the surface of
your work piece height (it can be useful to use pre-measured set-up blocks).
• Once the desired height is achieved, tighten the T-Handle knobs.
1/8” Rectangular Electrode Installation Procedure (Adjustable Gap) (Item #MEL AG)
Step 1: Position Electrode Clamp Plates
• Loosen the two screws on the front of the electrode holder. Reference Figure 8.3.
• Rotate and position the brass electrode clamp plates with the “half moon” shape facing outward and the
notched portion of the plate facing toward the electrode holder.
• Leave the screws loose.
Step 2: Insert Electrode Halves
• Turn the thumbscrew (C) on the right side of the electrode holder counterclockwise to open the gap
enough for an electrode to slide in between the two clamp plates. See Figure 8.3.
• Hold the two halves of the electrode together while inserting them into the slots between the clamp
plate and holder. Hold the halves at desired height.
•
each other, but not too tight yet.
Step 3: Adjust Weld Head Height
• Loosen the two T-Handle knobs on the right side of the unit. Reference Figure. 9.1.
• Turn the large circular knob at the back of the unit counterclockwise to raise or clockwise to lower.
•
• Lower the head until the tip of the electrode makes contact with the set-up block.
• Press against the top of both halves of the electrode to ensure that good contact is being made with
the surface of the block by the tips of both halves (ensuring the tips are even with each other).
• Once the tips are even, tighten the thumbscrew more to help keep the electrode halves from shifting.
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• 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” above the surface of your work piece height (it can be useful to use pre-measured set-up
blocks).
• Once the desired height is achieved, tighten the T-Handle knobs.
Step 4: Adjust the Gap Between Electrode Halves
• Turn the thumb screw on the right side of the electrode holder counterclockwise to increase the gap
between the halves of the electrode until the desired gap distance is reached (use a feeler gauge or
spacers to set the gap consistently each time).
• Sometimes if a very small gap is desired, a piece of paper or business card can be inserted between
the electrode halves to help act as a spacer (tighten the thumbscrew until the paper is sandwiched
between the two halves).
1/8” Opposed Electrodes Installation (Optional Accessory Required) (Item #EL125RWMA)
Step 1: Position Electrode Clamp Plates
• Loosen the two screws on the front of the electrode holder. Reference Figure 8.3.
• Rotate and position the brass electrode clamp plates with the “half moon” shape facing inward toward
each other.
• Tighten the screws .
Step 2: Insert Upper Electrode
• Turn the thumbscrew on the right side of the electrode holder counterclockwise to open the gap
enough for an electrode to slide in between the two clamp plates.
• Insert an 1/8” diameter electrode between the clamp plates and hold at desired height.
• Turn the thumbscrew clockwise to tighten the electrode in place (use pliers to ensure it is tight if neces-
sary).
Step 3: Attach Negative Weld Cable to Lower Electrode Assembly
• Remove the black weld cable from the Isolation block.
• Attach the cable to the back of the lower electrode holder (optional accessory/purchased separately)
Make sure the screw is tight.
Step 4: Attach and Align Lower Electrode Holder Assembly
• Remove the plastic cover from the front of the base (the plastic screws should pop out with a little
applied tension).
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• Loosen the (x4) screws on the base plate and slide the plate forward away from the base to remove it
completely from the assembly.
• Slide in the lower electrode holder assembly.
• Line up the hole in the lower electrode holder with the upper electrode.
• Lower the weld head until the upper electrode enters the hole in the lower electrode holder (make sure
• Tighten the (x4) screws on the base of the lower electrode assembly.
•
bending.
Step 5: Insert Lower Electrode
• Raise the weld head until there is enough space to insert an 1/8” diameter electrode into the hole in the
lower electrode holder.
• Hold the lower electrode at the desired height and tighten the screw on the right side of the holder to
clamp the electrode in place.
Step 6: Adjust the Weld Head Height
• Position the weld head such that the gap between the upper and lower electrodes can accommodate
the work piece and is no larger than 7/8”.
• Once the desired height is achieved, tighten the T-Handle knobs.
ELECTRODE CONFIGURATIONS AND TYPES
Opposed (Direct Weld)
the material. See Figure 13.1. Current passes from one electrode through both work pieces and out the op-
strength. An optional accessory (WH1 – Lower Electrode Holder Assembly) is required to perform this type of
weld. Electrodes come in Glidcop, molybdenum, and tungsten, with a variety of tip shapes.
Step (Adjustable Gap)
-
-
tip sizes and come in Glidcop or molybdenum.
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Series (Adjustable Gap/Fixed Gap)
weld.
Fixed Gap electrodes can be used for similar welding applications wherein an adjustable gap electrode might
every weld with no need to adjust the gap. Fixed Gap electrodes have a smaller gap, which can often be dupli-
molybdenum.
Thermocompression
-
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
-
plications.
Figure 13.1. Opposed
electrode conguration
example. Figure 13.2. Step
conguration example.
Figure 13.3. Series
electrode conguration
example.
Figure 14.1.
Thermocompression
electrode conguration
example.
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ELECTRODE TIP RATINGS
• .01” x .01” – 40-1000 grams
•
•
Stereo Microscope Set-up Guide
Ergonomics
The Stereo Microscope is mounted to a multi-position articulating arm that allows operators to position the
assembly to meet multiple set-up requirements. Adjustments can be made to change the viewing angle and
height of the eyepieces based on personal preference. It can take experimentation to familiarize yourself with
relation to table and chair heights.
Adjusting the Scope
The scope arm has four main adjustment points that can be utilized in conjunction with one another to achieve
that changing the position at one of these points will often result in a need to change the others.
1. Main arm angle
Secondary arm angle
3. Scope height
4. Scope focus
Follow these steps to make adjustments to the microscope:
Step 1: Set Eyepiece Angle
•
Step 2: Set Height
• Once the appropriate angles have been achieved, adjust the height of the scope assembly by loosening
the scope height twist knob (3) and raising or lowering the assembly.
• Tighten the knob once the desired height has been reached.
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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.
Step 4: Lock in Place
• If the eyepiece angle feels comfortable and the part is in focus, the screws on the arm adjustment
points can be tightened to ensure stability over time.
LED LIGHTS
The scope has built-in LED lighting that illuminates as soon as the unit is powered on. If the lighting is not de-
sired for any reason, simply unplug the cable from the connector on the side of the unit labeled “light”.
1
2
3
4
Main Arm Angle
Secondary Arm Angle
Scope Focus
Scope Height
Figure 15.1. Use these four adjustment points to achieve a comfortable viewing posture.
~36°
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Chapter 3: How to Operate the Micro E Weld Head
Warning: Review the Safety Guide that accompanied this weld head prior to
operation. The operator assumes all liability.
Software Interface
The Sunstone Micro E weld head interfaces with (is controlled by) an accompanying welding power supply. All
-
structions.
Compatible Welding Power Supplies
The Micro E Weld Head is designed to be used with the following Sunstone welding power supplies:
• Sunstone Pico DC
• Sunstone CDDP-A (Coming soon)
•
Verify All Cable Connections
Weld Cables: The red and black weld cables should be connected to the positive and negative terminals on the
welding power supply.
Foot Pedals: Depending on the desired set-up, one or two foot pedals will be connected to the back of the
Comm Cable:
back of the welding power supply in the “Accessory” port or per the welding power supply users manual.
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1
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