Linear DC Welder

 AIT offers the AVIO line of ultra precision Transistor Welders

CheckmarkProviding you with equipment and technical support
 DollarsignLower prices on equipment and electrodes than other manufacturers
ClockShorter lead time, especially on electrodes
WrenchFree test welds and unparalleled customer support

 

Click here for matching weld heads.

How We Can Help You
The best way to start shopping for a welder is to take advantage of our free test welds to help determine if a transistor welder is the proper weld equipment for your application.  We are an equipment and technical support provider for Nippon Avionics ( Avio ) brand of precision inverter welders.  At AIT, we have chosen the Nippon Avionics ( AVIO ) line of equipment because we have found that you get more advanced technology, quality, and precision for your money than with other popular brands.  We can provide the equipment you need at an economical price, and assist with any technical issues you encounter setting up your welding process.  Submit a contact form or call us today to request assistance with your next project.
 
 
AVIO Transistor Welders 

  • The favorite for welding micro wires and components

  • Consistent and precise welding by high speed linear control

  • 3 Feedback modes (constant current, voltage, or power)

  • High speed welding (up to 5 shots / second)

  • Pre-weld check function reduces spark problems

  • Simultaneous graph of voltage, current, and power wave forms

 

AVIO_Transistor_Type_MCW-700_welder
 
Features MCW-700 MCW-750
Maximum Current 500A 1800A
Maximum Voltage 2V 4V
Constant Current Mode 10 - 500A (1A Step) 10 - 1800A (1A Step)
Constant Voltage Mode 0.001 - 2V (1mV Step) 0.01 - 4V (10mV Step)
Constant Power Mode 10 - 500W (1W Step) 10 - 3600W (1W Step)
Weld Time : Up 0 -999 x 0.01ms or x 0.1ms
Weld Time : Weld 0 -999 x 0.01ms or x 0.1ms
Weld Time : Down 0 -999 x 0.01ms or x 0.1ms
Weld Time : Squeeze&Hold 9.99s (maximum) 9.99s (maximum)
Pre-Check Resistance/Current Resistance/Current
Shot / Sec 5shots / sec: 500W 2ms 5 shots / sec : 3600W 2ms
Monitor : Wave Form Current / Voltage / Power Current / Voltage / Power
Monitor : Current Average / Peak Average / Peak
Monitor : Voltage Average / Peak Average / Peak
Monitor : Power Average / Peak Average / Peak
Number of Conditions 15 15
Interface RS-232, I/O, analog output RS-232, I/O, analog output
Power Source (Option) 100-120V AC (200-240V AC) 100-120V AC (200-240V AC)
 
Real  Time Welding Wave Form Display
 
graph of wave form
 
 
 
PID Adjustment - Before and After
pid adjustment
 

Transistor welders are also known as Linear DC welders. In a transistor welder, energy is stored up in capacitors and released through transistors. This produces a result similar to the high frequency inverter power supplies. The output is in the form of clean square waves with very fast rise time. The transistor welders made by AVIO are closed loop designs, utilizing transistor controlled feedback with extremely fast response time, which are able to monitor the condition of the weld using one of three feed back modes, "constant current", "constant voltage", or "constant power". These feedback modes offer great advantages such as better process consistency between multiple weld stations, reduced number of bad welds, and real time automatic adjustment for variations in part thermal loading and plating. Linear DC welders do not use a transformer. These power supplies have the best low energy control, making them the favorite for welding micro wires and then foils. The major limitation is that the duty cycle is typically much less than one weld per second.

The Avio welders we are offering here are premium quality Japanese made welders. We stand by these welders and guarantee our customers support and assistance when you buy an Avio welder from us. All electrodes are manufactured by AIT in our facility in the United States. We can respond quickly to your inquiries or questions.

 
Welding Wave Form
 
welding wave form

 

 


 

 

 

 

 

 

 

 

 

 SUNSTONE LINEAR DC WELDERS

 

Sunstone Linear DC Welder
Sunstone DC-5 Welder

Sunstone Linear DC Welder

 
 
Sunstone has designed a completely unique closed-loop feedback resistance welding system that utilizes new technologies, giving the UC Linear DC welder the power of a High-Frequency Inverter and the precision of a Linear DC.  It does not require an external transformer, so it isn’t an HF welder, and it offers a greater range of settings than a typical Linear DC welder, yet is able to perform the same functions as both, and in most cases exceed those of other HF or Linear DC welders – offering high repetition rates, fine low-energy control, and short or long weld times – without  drawbacks.
 
The welder is highly adjustable to offer the most convenience to a wide variety of users allowing creation of custom software, ability to update and improve capabilities, features and functions effortlessly.
 
The UC linear DC can also introduce high-frequency agitation that provides additional weld penetration, more uniform metal crystallization, stronger weld joints, and can facilitate stronger weld joints with lower overall heat input.
 
 
Applications include
•Thermocouples
•Battery Pack Welding
•Coil Termination
•Relays
•Strain Gauge
•Aerospace Welding
•Honeycomb
•PCB Welding
•Electrical Components
•Sensors
•Injectors
•Magnet Wire Bonding
•Solenoids
•Transformer Coils
•Actuators
•Inductors
•Seam Welding
•Adding Material
•And More!
LINEAR-DC-WELDER
 
 
 

Features
 
•10-2500A weld current
•Roll Spot Capability
•Short Seam Segments
•Geared for Automation
•Weld data logging
•High precision linear DC welder
•No external transformer required
•Programmable Schedules and Jobs
•10” Capacitive Touch screen Interface
 
 
 
•Closed loop feedback and weld monitoring technology
•Graphical feedback display of current, power and voltage
•Updateable firmware
•Dual weld control
•LVDT (position) Feedback
•Force Feedback
•Data logging via USB and ethernet
•Smart heat weld overlay
•Customizable waveform generation
•Fine control over energy waveform
 
 
 
  LDC 1500W  LDC 3000W 
Nominal Line Voltage (Single Phase)
90-264 AC Version
 
180-264V
 
Duty Cycle
4%
 
8%
 
Current
10A -2500A 10 Amp/Step
 
10A -2500A 1 Step
 
Voltage
0.1V - 10.0 V at 10 mV/Step
 
0.1V - 10.0 V at 10 mV/Step
 
Power
0.01kW - 20kW 10Watt/Step
 
0.01kW - 20kW 10Watt/Step
 
Peak Current
2500 A
 
2500 A
 
Peak Voltage
10V
 
10V
 
Peak Power
20kW
 
20kW
 
Weld Period Ranges
weld time (each section)
Squeeze/Hold Periods
Ranges (msec)
0-100
0-5
Resolution (steps)
0.1 ms
1 ms
Ranges (msec)
0-100
0-5
Resolution (steps)
0.1 ms
1 ms
Current Output Accuracy
±10A
 
±10A
 
Voltage Output Accuracy
± 0.005V
 
± 0.005V
 
LxWxH
15.2x11.4x15.5in (38.5x28.9x39.3cm)
 
15.2x11.4x15.5in (38.5x28.9x39.3cm)
 
Weight
46.5 lbs (21.1kg)
 
46.5 lbs (21.1kg)
 

 

Sunstone DC-5 Welder

 
 
The DC 5 is a precision DC waveform welding power supply, capable of precise power delivery. It has a maximum output of 5 volts, and can be adjusted to deliver as low as 0.1 volts. It has a digital readout that shows the weld length and volts delivered. The DC 5 is able to deliver up to 60 welds per minute. This unit is excellent for fine wires and metal sheets, such as ribbons. The DC 5 is the perfect choice for control and precision.
 
Sunstone’s micro welding solutions are perfect for microjoining and thermocompression bonding. When bonding small wires or ribbon from one connection pad to another, Sunstone’s new DC 5 - welder in combination with a low-force micro weld head is recommended as an optimal welding setup.
 
 
 
Applications
 
• Thermocompression and Microjoining Bonding
• Magnet Wire Welding
• Enamel Coated Wires
• Wire to Chip Welds
• Solar Panels
• Fine Wires and Ribbons
 
 
 
DC-5 Welder
Features
• DC Waveforms
• Fine control of weld voltage
• Discharge Length
 
 
Peak weld current and External Cabling Gauge Number (AWG). Four and eight AWG cabling is typically seen when using hand held attachments.
 
DC Mode
TCB Electrode Pk Current Max
400A (500A w/ Larger Cabling)
TCB Electrode Pk Current Min
8A (5A w/ Smaller Cabling)

   

 

Weld Speeds

DC Mode
Rep Rate
35 welds/min @ 5v 100ms
Rep Rate
190 welds/min @ 2v 50ms

 

  

Weld Pulse Characteristics

 
  DC Mode
Min Output
0.1V
Max Output
5V
Pulse Width Min
0.5 m
Pulse Width MaX
500 ms
Rise Time (to Max Voltage)
1μs
Minimum Resistance
8 mOhm
 
Welder Physical Characteristics
 
    DC 5v
  Inches cm
Height 8
20.3
Width
8.5
21.6
Depth
11
28
Weight
17 lbs
8 kg