Abstract: An exit side pusher mechanism (10) for a flash butt welder (14) applies a pushing force which opposes the tendency of an leading strip (16) of steel to back away from a spacer bar (40) prior to welding. The pusher mechanism includes a rotating drive wheel (82) which frictionally engages the strip. The drive wheel is lowered into an engagement position by a pneumatically driven actuator (100). A pneumatically driven drive motor (84) rotates the drive wheel a preselected distance to advance the strip back towards the spacer bar.

Abstract: An electric resistance welder welds, hot reduces, tempers and planishes overlapped metal workpieces. The welder incorporates two transformers (50, 60) which are connected to two sets of wheel electrodes (26, 28 and 36, 38). Electric current from a first transformer (50) flows through workpieces (16) and returns through a second transformer (60). The first set of wheel electrodes (26, 28) creates a weld joint and the second set (36, 38), depending on the shape, area, and pressure of the wheels, either reduces the weld thickness, tempers the weld joint, or both. A control circuit (72) includes a current sensor (70) and power factor adjuster (80). The current sensor senses current flow through the first transformer during the welding process. As the current changes, particularly when the sets of wheel electrodes engage and disengage the workpieces, the power factor adjuster (72) adjusts the power factor to maintain constant heat to the workpieces.

Abstract: Welding apparatus including a tube of high resistance material brazed between two electrical conductive tubes connected to the secondary of a resistance welding transformer. Also included is a plastic element having a head projecting through a hole of a metallic element. By initiating forcible contact between the tube and the head of the plastic element, such head is heated, softens and becomes upset to form an interlock with the metallic element.

Abstract: Apparatus for simultaneously fusing both positive and negative side terminal posts of a lead acid storage battery having a pair of tombstones of L-shape. Each of the terminal posts has an inwardly extending projection extending into a substantially U-shaped opening at the top of the vertical legs of the tombstones. A pair of spaced induction coils are connected in series. A mold surrounds each coil for confining fused metal to fill the substantially U-shaped opening in the top of the tombstones for providing an integral connection between the terminal posts and the vertical portions of the tombstones when the terminal posts and tombstones are lifted into the molds and the induction coils are energized.

Abstract: Intercell fusing apparatus for use in a battery having flat tombstone type connections, each tombstone having a pair of vertically and horizontally outwardly extending portions of fusible material closely surrounding a vertical partition of electrically insulating material having a hole extending horizontally therethrough. It comprises a mold closely surrounding each pair of vertical portions of the tombstones and surrounding a partition portion above the hole, and a pair of interconnected coils preferably having double windings on each side of the partition to effect fusion of the tombstones within the mold when energized by a source of high frequency alternating current.

Abstract: In a storage battery having a plurality of electrically insulating vertical partitions, the method of the invention comprises sandwiching each partition, successively, between a pair of terminals of lead or other easily fusible material of the so-called "tombstone" type, that is, of "L" shape in which the vertical or riser portion of one terminal has a horizontal pin which extends through a hole in the partition and through a hole in the riser portion of the other terminal. An insulating sheet and induction coil are placed against the end of the pin by a fusing apparatus which is provided with a pair of arms which are pivotally operated by a fluid cylinder, one arm carrying the above-mentioned coil and insulating sheet and the other acting as a pusher.

Abstract: A method of making intercell connections in a lead-acid storage battery. The battery has a plurality of pairs of vertical risers of lead or other readily feasible material, each pair sandwiching an electrically insulating vertical partition. The method comprises forming a horizontal hole in a partition, squeezing together such as by hydraulic cylinders, a pair of risers against its corresponding partition and applying coils energized by high frequency electrical current against the outer surfaces of the risers adjacent the hole and simultaneously squeezing together said pair of risers against its partition so as to fuse the riser material adjacent the hole and introduce it through and fill the hole. High quality readily reproducible intercell connections are thus formed successively throughout the battery.

Abstract: Apparatus and method for induction heating "over-the-partition" intercell connections in a lead/acid storage battery by melting both lead risers so as to form a connection over the top of the insulating partition. A mold is suspended on top of the partition and an induction coil is supported on the mold so as to surround the top portion of the intercell lead risers. High frequency alternating electrical current is applied to the coil so as to melt the top portion of the lead risers so that upon fusion thereof in the mold and cooling, the tops of the risers are interconnected. The interconnection bridges the top of the risers and rests on top of the partition. The invention lends itself to mass production in a very short time as compared to present methods. Excellent fusion quality is reliably obtained as compared to present methods.

Abstract: An adhesive bonding press having a "C" frame which mounts upper and lower platens, one of which supports an induction coil mounted in a non-metallic tube. Adhesive is applied to coat the top surface of a lower metallic plate supported on the lower platen, after which a second metallic plate is laid thereon. Thereafter, the plates are clamped together by an air cylinder through upper and lower platens and tooling holders of the press, one of which includes an induction coil. High frequency current is then applied to the induction coil which rapidly heats the adhesive for 2 to 3 seconds. An air blast is then induced in the upper and lower tooling to rapidly cool the parts to room temperature. Spot curing takes place in the area axially of the induction coil which very firmly bonds the two plates together so that further operations in a production or automation line will take place immediately.

Abstract: In a flash butt welder for joining strip ends, the improvement for improving the quality of flash butt welds made in specialty grade steels, such as high strength low alloy, as well as for considerably reducing the upset current requirement, by applying a protective atmosphere of combustible gas, such as propane, natural gas, or hydrogen during the flash butt welding process. Welds free from any detectable defects can be made with lower upset current densities thus extending the equipment welding capacity.

Abstract: A Robot type resistance welder of very large capacity that enables the electrodes of the welder to be readily adjustable in the welding and retracting strokes and automatically controlled so as to retract when encountering an obstacle - also whereby the degree of retraction of electrodes may be selectively controlled and whereby the vertical elevation of the work plane may be varied during welding in accordance with the contour of the work, such as a curved panel. The respective electrodes of the spot welders have supporting arms which are pivotally interconnected together with an operating air cylinder. An adjustable stop is provided in the air cylinder to adjust the extent of retraction. The entire assembly including the pivotal supporting arms and inter-connected cylinder are provided with an adjustable stop for limiting the pivotal movement of the assembly. Such pivotal movement is cushioned by springs.

Abstract: A welding machine auxiliary transfer clamp for pushing the end of a coil against a spacer bar and including a pair of clamping elements, each including a cylindrical ram operated by fluid cylinder, there being a ball connection intermediate each fluid cylinder and its respective ram to enable the upper and lower rams to pivot freely about their longitudinal axis so as to prevent occurrence of a gap otherwise formed by lateral tilting of the coil, whose end is to be welded.

Abstract: A spacer plate construction for use in selective spacing between the head end and tail end of strips to be welded end-to-end by a welding machine.Sensors in the form of spring biased pivotal (or otherwise moveable) elements are mounted in longitudinally spaced cavities in the spacer plate to assure that the strip ends are held flush against the spacer plate before clamping for subsequent flash or butt welding. It is only when the sensor elements are moved inwardly to the sides of the spacer plate sufficiently to actuate a proximity switch mounted within the sensor plate that a circuit for initiating clamping of the head end and tail end of the strips can be initiated for subsequent welding.

Abstract: A flash welding machine which comprises two pairs of current-carrying welding electrodes, one pair movable and the other, stationary. A double cut guillotine shear is normally positioned forwardly and alongside the welder at a "stand-by" position, remote from the welding position to avoid splattering from welding sparks. When it is desired to shear and weld, carriage means move the shear longitudinally alongside the machine and then laterally into a gap formed by moving the movable pair of welding electrodes from the stationary pair. Depending upon the selected gauge bar of a ladder-like gauge bar construction mounted on each side of the shear when in the "stand-by" position, such selected gauge bars are clamped between the lower current-carrying dies and the lower blades of the shear so as to provide back-up support for such blades as well as to tightly clamp the selected gauge bars for accurate gauging of the projection of strip desired beyond the welding dies after shearing.