Abstract: An appartus and method for a stud welder power source is disclosed. The power source has a control circuit connected to an inverter which converts an electrical signal from a power source into an electrical signal that can perform stud welding. The inverter conditions the power signal such that a current of at least 1000 amps can be generated nearly instantaneously. Additionally, having a power source that includes a control circuit with an inverter allows for a smaller and lighter appartus when compared to known stud welders.

Abstract: A fastener assembly comprises a stud bolt including a bolt portion and a weld end to be welded to a workpiece, and a nut member to be screwed into the stud bolt. The nut member screwed into the stud bolt before welding is formed out of an electrically conductive material to allow the welding current to flow through the nut member into the stud bolt and weld the nut member to the workpiece while connected to the stud bolt. Then an attachment member is disposed on top of the workpiece, and the attachment member is fastened to the workpiece when the nut member is turned in the fastening direction.

Abstract: A portable weld stud system is disclosed. An embodiment of the system includes a housing with a power source, which may be four twelve-volt sealed lead-acid batteries with fifty-two amp-hours of capacity. The housing includes a user interface and a set of power terminals that are coupled to the power source via a control module and a control terminal. Leads couple the housing to a weld stud gun and a work surface. A trigger on the weld stud gun allows a user to generate a drawn-arc weld between a weld stud in the weld stud gun and the work surface. The housing may include an active thermal management system and an internal charging system. The housing may further include a recess that may be covered with a removable door and is configured to accept various components such as leads, power cords, weld studs, and/or weld stud guns.

Abstract: The invention relates to a joining head arrangement for joining components, such as studs, onto a workpiece. The joining head arrangement comprises a housing and a slide that is mounted on the housing and is movable, by means of a linear drive, in a joining direction in relation to the housing. The joining head further comprises a component holder, arranged on the slide, and operable to hold a component during a joining operation. A feed device delivers components, at a transfer location, to the component holder. The component holder is rotatable about an axis, which is aligned transversely relative to the joining direction, from a transfer position to a joining position.

Abstract: An underwater fastener welding apparatus that includes a welding tool positioned within a watertight housing. The housing includes an inlet coupled to a source of pressurized gas. The housing is pressurized to balance a pressure internal to and external to the housing when the underwater welding apparatus depth level is changed.

Abstract: A joining device for joining two parts by welding has a joining head including a lift device for linear transport of a joining unit along a lift axis relative to the joining head. The joining device executes a joining operation by transporting the joining unit out of a lift position towards a base position. The joining unit includes a boom extending outside of the joining head, at a free end of which the joining operation takes place offset and parallel to the lift axis. The joining unit is oriented relative to the joining head such that the joining unit runs out relative to the joining head in the lift position.

Abstract: A collet and nut assembly for a stud welder in which the body of a tubular nut has an extension sleeve that surrounds a tubular collet having longitudinal tangs separated by slots. Relief holes at base ends of the slots are inside the nut, and maximum stress on the collet is redistributed away from the relief holes. The nut may have a further tubular extension forming a cover for the collet, with a face that protects the tip of the collet from weld spatter and soot. The cover also protects the collet from heat.

Abstract: A joining system head is provided for fixation to a movable frame, in particular to a robot having a holder for an element to be joined to a part. A joining drive moves the holder along a joining direction for joining. The holder is mounted on the joining system head and is rotatable about an axis running transverse to a joining direction.

Abstract: A stud welding apparatus includes a power supply and a stud welding tool having a welding head portion and a cable receiving portion. A composite cable having first and second ends is coupled at a first end to the stud welding tool at the cable receiving portion and to the power supply at the second end of the composite cable. If the stud feeder is present, the second end of the composite cable can be coupled to the stud feeder. The composite cable includes a conductor having no individual electrical isolation and at least one control lead electrically isolated from the conductor. The conductor and the at least one control lead are surrounded by an outer non-conductive layer.

Abstract: A chuck assembly for a stud welding gun includes a current passing member parallel to and separated from an electrically isolated member forming a stud retaining gap. The current passing member provides a path for a welding current and includes a contact surface for releasably retaining and transmitting the welding current through a shank of a weld stud. The welding current only passes through the current passing member into the shank of the stud.

Abstract: The present technology relates to adjustment mechanisms for control settings on stud weld tools. Stud welding tools typically have a body that comprises a handle, a front end and a rear end. In one aspect, the present technology relates to plunge adjustment mechanisms for stud welding tools that are located at the front end of a stud welding tool and provide an adjustment knob for manual plunge adjustment. Another aspect of the present technology relates to weld heat adjustment mechanisms for stud welding tools that are located at the rear end of a stud welding tool and provide an adjustment knob for manual weld heat adjustment.

Abstract: A fastening system with a weld stud having an annular weldment portion and a fracturable nut is provided. The fracturable nut and stud construction is configured to fail under torsional load prior to the structural parts failure.

Abstract: A welding stud apparatus and method of manufacturing a welding stud are disclosed. The welding stud has a weld end constructed to be welded to a workpiece that has at least one recess formed therein. The recess decreases an effective arc area of the weld end to localize a current therethrough and increase the efficiency with which the welding stud can be welded to a workpiece.

Abstract: This invention relates to a ferrule dispenser for dispensing stud welding ferrules and to a package of ferrules for use with the dispenser. The dispenser comprises a rod that supports a spring loaded cam system. The cam system moves relative to the rod and includes a compression spring and a cam. The spring and cam work together to bias a pair of ferrule release pins inward and outward of the rod, selectively holding ferrules on an outer surface of the rod or releasing them onto a work surface. The package of ferrules used with the dispenser includes multiple sets of ferrules, each set including multiple ferrules uniformly stacked on a spindle. Each spindle has one open end that can pass through an opening in a handle of the dispenser and down a center bore of the dispenser for loading the ferrules from the spindle onto the dispenser.

Abstract: A gas turbine rotor and a method for manufacturing a gas turbine rotor having integral blading, is disclosed. A rotor blade has a blade pan and a blade footing connected to the blade pan. The blade footing is designed with a V-shaped cross section in at least some portions and the blade footing is welded to a rotor mount by capacitor discharge welding.

Abstract: The invention relates to a stud welding method, particularly for welding without a supporting foot, which makes it possible to securely detect the presence or the absence of a part to be welded in the stud holding device. For this purpose, in a first embodiment of the method, the stud holding device is first positioned in a pre-determined distance relative to the surface of the workpiece without a part to be welded. Then, a part to be welded is supplied. When the welding axle moves towards the workpiece, the distance which has to be covered until the part to be welded contacts the workpiece is detected. On the basis of the previously determined distance between the stud holding device and the workpiece and on the basis of the distance covered conclusions on the presence or the absence of a part to be welded may be drawn. In another embodiment, the stud holding device is moved towards the workpiece together with a part to be welded until a contact is detected.

Abstract: A stud weld head includes an electrode with a base for attaching the electrode to the stud welder; a body extending from the base and having a stud receiving cavity; and a retention device associated with the stud receiving cavity to permit entry and removal of a stud from the cavity without contact with the retention device. The improved stud weld head retains the stud during the welding operation reducing the chances that the stud inconveniently falls out of the stud receiving cavity.

Abstract: A fastening system is providing, the fastening system has a weld stud having an annular weldment portion and a fracturable nut. The fracturable nut and stud construction is configured to fail under torsional load prior to the structural parts failure.

Abstract: A holder for a stud portion of a stud has a polygonal cross section, in particular for use in an apparatus for stud welding. The apparatus includes a fastening portion fixed to the stud-welding apparatus, and having a retaining portion which has a multiplicity of retaining tongues which extend substantially in a longitudinal direction. The retaining tongues can be elastically bent in a direction transverse to the longitudinal direction in order to receive and elastically retain the polygonal stud portion between them. At least two of the retaining tongues form a slot between them. At least a portion of the slot runs in a helical manner.

Abstract: A portable weld stud system is disclosed. An embodiment of the system includes a housing with a power source, which may be four twelve-volt sealed lead-acid batteries with fifty-two amp-hours of capacity. The housing includes a user interface and a set of power terminals that are coupled to the power source via a control module and a control terminal. Leads couple the housing to a weld stud gun and a work surface. A trigger on the weld stud gun allows a user to generate a drawn-arc weld between a weld stud in the weld stud gun and the work surface. The housing may include an active thermal management system and an internal charging system. The housing may further include a recess that may be covered with a removable door and is configured to accept various components such as leads, power cords, weld studs, and/or weld stud guns.

Abstract: The invention relates to a stud welding method, particularly for welding without a supporting foot, which makes it possible to securely detect the presence or the absence of a part to be welded in the stud holding device. For this purpose, in a first embodiment of the method, the stud holding device is first positioned in a pre-determined distance relative to the surface of the workpiece without a part to be welded. Then, a part to be welded is supplied. When the welding axle moves towards the workpiece, the distance which has to be covered until the part to be welded contacts the workpiece is detected. On the basis of the previously determined distance between the stud holding device and the workpiece and on the basis of the distance covered, conclusions on the presence or the absence of a part to be welded may be drawn. In another embodiment, the stud holding device is moved towards the workpiece together with a part to be welded until a contact is detected.

Abstract: A short resistant welder that includes, in some embodiments, a short circuit sensor configured to transmit a first signal indicative of a short circuit between a workpiece and a stud, and a stud welding controller communicatively coupled to the short circuit sensor. In certain embodiments, the stud welding controller is configured to transmit an increase-current control signal to a power supply in response to the first signal.

Abstract: A system having a power source and a welding stud positioning controller configured to cooperate with the power source to output first, second, and third current levels one after another to a welding stud positioning device. In some embodiments, the welding stud controller may be coupled to the power source, and the first, second, and third current levels may be different from one another.

Abstract: A process and a system are proposed for short-time arc-welding elements, such as for example metal studs, on to components, such as for example metal sheets, wherein an element in the context of a welding operation is initially raised in relation to the component, a welding arc is formed between the element and the component, and the element is lowered again, the lifting height of the element in relation to the component being detected at least within a time segment between raising and lowering of the element. The initiation of the lowering operation and/or the lowering operation itself is controlled as a factor of the detected lifting height such that a previously specified total welding time is achieved.

Abstract: A joining system head (22) is proposed for fixation to a movable frame (12), in particular to a robot (12), having a holding means (66) for an element (36) to be joined to a part (38), a joining drive means (64) to move the holding means (66) along a joining direction (40) for joining, and a feeding means (44) for feeding elements (36) to the joining system head (22). Here a control means (42) to control the joining drive means (64) is arranged at the joining system head (22) spatially distanced from the holding means (66) and the joining drive means (64), so that the holding means (66) and the joining drive means (64) form a joining tool (32) of small dimensions, and means (68) are provided to pass on the elements (36) fed to a transfer station (46) of the feeding means (44) in each instance to the holding means (66) from in front.

Abstract: A weld stud includes a cylindrical body having an outer surface and opposing first and second ends. At least one groove is formed in the outer surface of the cylindrical body. The groove extends helically about the cylindrical body from the first end toward the second end of the cylindrical body. A thread is formed on the cylindrical body and extends longitudinally from the first end towards the second end of the cylindrical body. The thread projects radially outward from the cylindrical body.

Abstract: A welding apparatus is presented that includes a post-firing detection system and control connected to communicate with the post-firing detection system such that a stud welding gun is prevented from activation if a recently fired welding stud remains connected to the stud welding gun.

Abstract: A feed device for fastening elements with low length-to-diameter ratio has a hollow clamp into which individual fastening elements are inserted through a feed channel. The clamp has an internal pocket for pre-positioning a fastening element. A piston moves through the feed channel to engage the fastening element and to open the clamp to release the fastening element for further movement by the piston.

Abstract: A welding stud is attachable to a workpiece at a work end portion shaped for enhanced attachment strength with the workpiece. The welding stud has a portion of reduced thickness along a body portion between the work end portion and a retaining collar. The reduced thickness portion is furnished to yield or bend in the event of contact by some other body or piece and preserve the integrity of the attachment weld. The work end portion may also have an enlarged contact face with increased surface area for forming the weld.

Abstract: A hand welding device for short-time arc welding of elements, such as metal studs, onto parts, such as metal sheets, having a handlable housing, a holding means mounted on the housing to hold an element to be welded onto a part, a reciprocating means mounted on the housing to advance and restore the holding means relative to the housing, and positioning means mounted on the housing to maintain a predetermined distance from the part, is proposed. Further, a corresponding welding apparatus having such a hand welding device and a welding gauge fastened to the part, is proposed. Here the positioning means are offset to the rear relative to the anterior end of the holding means, so that the positioning means are suitable for being supported on the welding gauge to maintain the predetermined distance. For this purpose, a vertically adjustable stop is provided on a welding gauge according to the invention.

Abstract: A method of welding a stud (11) is provided. In another aspect of the present invention, a welding system is provided for a weld stud (11). A further aspect of the present invention employs a weld stud (11) with a substantially conical end section (29).

Abstract: In an arc stud welding device and method, after initial contact of a stud with a component (welded component) to which it is to be welded, the stud is lifted by an amount that permits a proper arc to be formed, even if the welded component was depressed by the initial contact with the stud. After melting of the tip of the stud and a portion of the welded component, the stud is pressed securely into the welded component to weld the stud to the welded component, with the welded component being depressed by the stud to an extent greater than that caused by the initial contact.

Abstract: A short-time arc welding system and method for welding elements on parts includes: a robot having an arm moveable in at least one coordinate axis; a welding head mounted on the arm having a holding device to hold an element, and a lifting device for advancing and returning the holding device, and; a measuring system for determining a relative position between the part and the element. The measuring system includes: a foot mounted on the welding head which contacts the part during operation to determine the relative position; and a positioning device to position the foot relative to the element in at least two different operating positions. A storage device stores a plurality of welding positions. The measuring system positions the foot in an operating position for each stored welding position.

Abstract: An arc stud welding device and method are provided, in which a stud is pulled up to an appropriate predetermined height, even after a portion of a flexible base material is dented by the stud and has returned to an original flat condition. A controller operates a linear motor to disengage the stud from the base material, operates a power source to generate a pilot arc and a main arc, and reverses the operation of the linear motor to press the stud against the base material for welding. When the stud is pulled up from the base material, the controller detects the position of disengagement of the stud from the base material, and the linear motor pulls up the stud to a predetermined position.

Abstract: The invention relates to a method of monitoring the welding operation in a stud welding process, wherein a part (19) to be welded is immersed into the melt by moving the part (5) towards a workpiece (17), with a physical quantity depending on the force required for moving the part (5) being measured at least during the phase of immersion of the part (19) to be welded into the melt and the measured gradient of the physical quantity plotted against time being compared with a predetermined set gradient. Furthermore, the invention relates to a stud welding device for carrying out such a method.

Abstract: A short-cycle arc-welding system (10) and a method for welding elements (32), such as metal bolts (32) to components (34) such as sheet metal (34) includes a robot (12), having at least one arm (16) displaceable on at least two co-ordinate axes (x, y, z), a welding head base (20) fixed to robot arm (16), a welding head (22) displaceably mounted on welding head base (20), a retaining device (30) retaining an element, a lifting device (36) for setting and re-positioning retaining device (30) in relation to welding head (22), and a measuring system (44,46) determining the relative position between component (34) and element (32). Measuring system (44,46) has a control device (46), controlling lifting device (36) such that element (32) displaces towards component (34) until contacting component (34) to determine the relative position.

Abstract: A device and a method for short-cycle arc welding of elements (26) to components are disclosed, with a positioning mechanism (14) that holds a welding head (28) and can be positioned relative to a component (12), wherein the welding head (28) has a chucking mechanism (32) for holding an element (26), a linear motion mechanism (58) for advancing and retracting the chucking mechanism (32) relative to the welding head (28), and a feed channel (30) for feeding elements (26) to be welded into the chucking mechanism (32). The chucking mechanism (32) has radially movable chucking elements (34) that can be moved by a chucking means between an open position which permits axial passage of an element (26) from the feed channel (30) through the chucking device, and a chucking position in which an element (26) is chucked between the chucking elements (34).

Abstract: Proposed is a joining system (10) as well as a method of operating a joining system (10) for joining elements (20) onto components (22), in particular for the short-time arc welding of elements (20), such as metal studs (20), onto components (22), such as metal sheets (22), having a central unit (12), which comprises a control device (30) and connectable to which is at least one joining unit (14) from a selection of different joining units, each of which comprises at least two modules (16, 18). The control unit (30) is designed so as to recognise (S16, S28) the mutual compatibility of the at least two modules (16, 18) of a connected joining unit (14) as well as the compatibility of the connected joining unit (14) with the central unit (12).

Abstract: A welding gun 10 has a collet for holding a stud with a flange and a shank at the tip of the welding gun. The collet comprises a tubular first collet member 17, secured to the tip, which elastically opens to a larger diameter than the stud flange, for holding the flange at the tip, and a tubular second collet member 22, secured to the tip of a piston rod 21 which extends from an air cylinder 11 provided in the aft portion thereof toward the first collet member, for, by the movement of the piston, picking up, accommodating, and holding the shank of a stud fed with its flange to the fore inside the first collet member 17.

Abstract: The invention relates to a rapid arc welding system (10) for welding elements (12) onto components (14). The inventive system comprises a welding head (16), a supply device (24) for supplying elements (12) to the component (14) and a control and power device (20). Said control and power device comprises a safety circuit for controlling the safety functions of the welding system (10) which allows an operation that is especially safeguarded from unauthorized use of the system in which an operation disruption is partially cancelled. In this partial operation mode, individual components of the system (10) can be activated selectively, especially for the purpose of maintenance.

Abstract: What is proposed is a joining system head (22; 170) for fixation to a movable frame (12), in particular to a robot (12), having holding means (66; 174) for an element (36) to be joined to a part (38), and joining drive means (64; 175) to move the holding means (66; 174) along a joining direction (40; 176) for joining. The said holding means (66; 174) is mounted on the joining system head (22; 170), rotatable about an axis (34) running transverse to the joining direction (40; 176).

Abstract: The invention relates to a short-cycle arc welding system comprising a robot having at least one arm which can be displaced in at least one coordinate axis (x, y, z), a welding head which is positioned on the arm and on which a holding device or holding an element and a lifting device are provided, said lifting device moving the holding device back and forth in relation to the welding head and a measuring system for determining the relative position between a component and an element which is held by the holding device and is to be welded to the component. Said measuring system comprises a foot which is mounted on the welding head and which is embodied in such a way that, during operation, it is in contact with the component in order to determine the relative position between the element and the component.

Abstract: According to a first embodiment of the method, the stud holder is first positioned without a part to be welded at a certain distance from the tool surface. A part to be welded is then provided. When the welding axle moves towards the workpiece, the path that needs to be travelled in order to bring the part to be welded and the workpiece into contact is detected. Conclusions regarding the presence or absence of a part to be welded are then drawn, based on the previous distance between the stud holder and the workpiece and the path travelled. According to another embodiment, the stud holder is moved towards the workpiece with a part to be welded until contact is detected. If, after contact is detected, further movement of the welding axle is possible as a result of the part to be welded being pushed into the stud holder, this is interpreted as an indication of the presence of a part to be welded.

Abstract: A process and a system are proposed for short-time arc welding, in particular for stud welding, with the step of sampling a welding parameter, in particular the arc voltage (U), during at least one time segment (Ts) of the welding operation, in order to detect disturbances, wherein the measurement curve determined from the sampling operation is smoothed and subsequently wherein at least one tolerance curve is generated which lies at a previously adjustable distance from the smoothed measurement curve, and subsequently the unsmoothed measurement curve is compared with the tolerance curve in order to detect high-frequency disturbances.

Abstract: A stud welding gun includes a closed conductivity path indicating a stud properly positioned for welding. Another aspect includes a conductivity detection circuit closed when a stud is present. A further aspect provides a method to operate a stud welding gun including closing a conductivity path to permit a welding operation. A still further aspect provides a method to detect a stud presence by passing a conductivity current from a conductivity detection circuit through a conductivity path closed by a stud.

Abstract: A system is disclosed for installing an insert within an aperture in a workpiece, the workpiece having a first side and a second side. The insert is the type in which a portion of the insert plastically deforms on the second side of the workpiece upon application of a linear force provided by a tool, thereby preventing withdrawal of the insert from the aperture. The insert comprises a sleeve member and an integral flange, where the flange has a larger diameter than the aperture. The disclosed installation system performs two actions. It causes the expansion of the sleeve and it also causes the flange of the insert to be fused or welded to the first side of the workpiece. The welded connection between the insert and the workpiece prevents any rotation or spinning of the insert within the workpiece, and increases the integrity of the insert-fastener connection.

Abstract: A stud welding device (1) with a stud holder (3) having a pointed region (2) for holding a weld stud (4) and a device (5) designed as an insulating spacing means with a rim (7). The pointed region (2) of the stud holder (3) always remains behind the rim (7) of the spacing means, thereby preventing electrical contact between the pointed region (2) and a component (6). The stud welding device (1) is reduced in size because it is formed without a support foot.

Abstract: The invention relates to a method for positioning a welding bolt (15), held in a bolt welding head (3), whereby the robot (5), to which the bolt welding head (3) is fixed, moves the bolt welding head sideways until a touch sensor (21) contacts a side wall (25) of a workpiece. The position of the side wall (25) is thus detected and the bolt welding head (3) can be moved through a set amount (Y) into a welding start position, from whence the welding bolt (15) can be welded to the workpiece (9) by the displacement in the direction of travel (V). The welding bolt (15), thus, always has the required separation (Z) from the side wall (25), independent of tolerances in the workpiece.

Abstract: A reinforcement butt stud welding method and a device therefore, capable of butt-welding a stud reinforcing bar coaxially to the end portion of a horizontally-laid existing reinforcement in a small work space; and a repairing/expanding method for a ferroconcrete structure. The reinforcement butt stud welding method includes the steps of fitting an earth clamp over the periphery of the end portion of the existing reinforcement, fitting an annular stud base that is a heat-resisting, insulating material to the conductor surface of the earth clamp by being pressed against the conductor surface, bringing the tip end of a stud reinforcing bar, loaded in a stud welding gun, into contact with the end face of the existing reinforcement, and keeping a ferrule disposed around the tip end portion of the stud reinforcing bar joined to the stud base to complete stud welding.

Abstract: The invention relates to a method of manufacturing a welding stud from a wire by cold-working and by hardening and tempering. The welding stud particularly serves to be welded to a workpiece by means of an electric stud welding method and consists of a mounting portion and a welding portion. According to the invention, the wire is first pre-treated by hardening and tempering and is then cold-worked in such a way that the mounting portion and the welding portion have different strengths.