Abstract: A cap extractor for a welding gun includes a housing, a pair of springs, and first and second arms that are arranged between the springs. Each of the first and second arms have teeth that are configured to engage a welding cap. The first and second arms are configured to move relative to the housing in first and second directions that are transverse to one another by deflecting the springs.

Abstract: A securing system, such as a welding system, includes a robot configured to transfer a part to a home position. A securing station has a frame and a gun supported on the frame. The gun includes first and second members movable relative to one another, which are first and second weld gun electrodes, for example. The gun is configured to secure a component to the part in a securing position during a securing operation. A float assembly interconnects the gun to the frame and is configured to permit the gun to glide relative to the welding frame between the home position and the securing position. A homing assembly includes a homing guide configured to release the welding gun from the home position during the securing operation, such as resistance welding fasteners to sheet metal workpieces.

Abstract: A cap dispenser for a welding gun includes a sleeve that slidably receives a drawer that is configured to house a column of weld caps. The cap dispenser also includes a spring that cooperates with a slide block that is arranged in the drawer. The spring urges the slide block toward an aperture in the drawer that is configured to receive a welding gun electrode.

Abstract: A conveyor for ferrous workpieces includes a frame. A static bed is affixed to the frame. The static bed has a workpiece support portion constructed from a non-magnetic material. The workpiece support portion defines a workpiece flow path. A drive assembly is arranged beneath the workpiece support portion. The drive includes multiple discrete magnets configured to move in a direction of the workpiece flow path. At least one guide rail extends upward with respect to the workpiece support portion on a side opposite the drive assembly. The guide rail is configured to orient a workpiece to a desired position with respect to the workpiece flow path.

Abstract: A securing system, such as a welding system, includes a robot configured to transfer a part to a home position. A securing station has a frame and a gun supported on the frame. The gun includes first and second members movable relative to one another, which are first and second weld gun electrodes, for example. The gun is configured to secure a component to the part in a securing position during a securing operation. A float assembly interconnects the gun to the frame and is configured to permit the gun to glide relative to the welding frame between the home position and the securing position. A homing assembly includes a homing guide configured to release the welding gun from the home position during the securing operation, such as resistance welding fasteners to sheet metal workpieces.

Abstract: A gas dynamic spray unit is provided that includes gun housing halves secured about a heater assembly. The heater assembly includes a one-piece, multi-passage ceramic heater core. The heater assembly is retained within the gun housing using locating features provided on the heater assembly and the gun housing. The heater assembly includes a heater housing at least partially surrounding the heater core. A biasing member biases the ceramic heater core toward a tapered outlet, which is provided by a deflecting cone surrounded by an insulating cone.

Abstract: An upper electrode assembly for welding fasteners includes a body that supports an electrode that has an aperture. The aperture is configured to receive a movable pin of a lower electrode assembly arranged opposite the upper electrode assembly. The lower electrode assembly supports a fastener in a welding position. The upper electrode assembly includes a position sensor which includes a position sensor member that is arranged in the body and is configured to cooperate with the pin to detect a fastener welding characteristic.

Abstract: An assembly system, such as welding system, includes an assembly station that is configured to assemble a component to a part in a loaded position. A drag conveyor includes a movable conveyor member that supports multiple locating elements configured to cooperate with a locating feature on a part. A friction bar is arranged along the locating elements, and the locating elements extend beyond the friction bar. The friction bar is configured to support the part and reorient the part from an unoriented position to an oriented position while the movable conveyor member drags the part along the friction bar. A robot is configured to transfer a part from the oriented position on the conveyor to the loaded position at the assembly station, such as a welding unit.

Abstract: An upper electrode assembly for welding fasteners includes a body that supports an electrode that has an aperture. The aperture is configured to receive a movable pin of a lower electrode assembly arranged opposite the upper electrode assembly. The lower electrode assembly supports a fastener in a welding position. The upper electrode assembly includes a position sensor which includes a position sensor member that is arranged in the body and is configured to cooperate with the pin to detect a fastener welding characteristic.

Abstract: A welding electrode according to the disclosure includes a body. A head is secured to the body and includes an aperture through which a pin extends. A polymer insulating sleeve is arranged between the pin and the head, for example. The sleeve material extends radially from an inner diameter to an outer diameter. The outer diameter engages the head, and the inner diameter is in close proximity to and engagement with the pin, which slides axially relative to the sleeve. The head and sleeve include first and second interlocking features that cooperate with one another to retain the sleeve in the aperture. The sleeve is arranged inboard from an outer face of the head, which is used to support a work piece.

Abstract: A resistance welding gun is provided that includes an arm assembly having spaced apart plates. First and second spaced apart blocks interconnect the plates and extend between the plates in a first direction. The first and second blocks are machined to provide a desired spacing between the plates. An electrode arm is arranged between the plates and blocks and supports an electrode end having a replaceable cap in one example. A clamping device applies a clamping load in a second direction transverse to the first direction to secure the electrode arm between the blocks. Lateral alignment between opposing electrode ends is achieved by a movable adjustment assembly on one of the arm assemblies. A pivot pin interconnects the block and electrode arm for permitting rotation of the electrode arm relative to the block. In one example, the adjustment assembly includes an adjustment member that is rotated to laterally move the electrode arm about the pivot pin in a desired position.

Abstract: A weld cylinder having a single piston arrangement is provided. The cylinder has a movable retract piston assembly with the piston arranged within the retract piston assembly. The piston supports a rod that is movable between home, intermediate, work, and advanced work positions. The rod moves rapidly from the home position to the intermediate position however, the rod moves more slowly from the intermediate position to the work position to reduce the impact force. A cushion chamber slowly exhausts through a pre-orifice and a hole in the cushion valve while an isolator is in an open position. Once the cushion valve opens in response to a retract-forward pressure on the cushion valve, the cushion chamber exhausts rapidly so that weld force increases rapidly to minimize increases in cycle time. Advance of a retract piston assembly is also cushioned. A weld-forward port is no longer provided on a cylinder barrel.

Abstract: A gas dynamic spray unit is provided that includes gun housing halves secured about a heater assembly. The heater assembly is retained within the gun housing using locating features provided on the heater assembly and the gun housing. An outlet fitting is secured to the heater assembly and supports a nozzle having a venturi that accelerates a carrier gas. The carrier gas is supplied to the nozzle by a passageway. A powder feed passage communicates with the nozzle to provide powdered material to the accelerated carrier gas, which is expelled from a tube. The passageway includes an aperture for leaking carrier gas inside the gun housing to pressurize the gun housing and prevent powdered material from infiltrating the gun housing. A shroud is secured to the gun housing about the tube to prevent damage to the tube and protect the user from contacting the hot nozzle and tube.

Abstract: A cold spray nozzle assembly includes a venturi having converging and diverging portions interconnected at a throat. An air supply conduit is in communication with the venturi for supplying a carrier gas to the converging portion. A powder feed tube is in communication with the venturi for supplying a powder material. An adjustment member is arranged within the venturi and is axially moveable relative thereto between multiple positions. The multiple positions respectively provide multiple different areas or throat clearances including a desired area between the adjustment member and the venturi or throat clearance. As a result, the adjustment member can be axially positioned to achieve desired gas pressures, deposition rates, and accommodate machining tolerances and component wear based upon the selected area. A retention member maintains the adjustment member in the desired position during operation of the cold spray nozzle assembly.

Abstract: A tooling fixture is disclosed that includes a weldment having spaced apart lateral members interconnected by opposing side members. Spaced apart trunnions support the side members for rotation about an axis, in one example. A locating pin is arranged between each side member and trunnions to enable quick and accurate location of the tooling fixture relative to the trunnions. The pins are at a right angle relative to the axis, in one example. Tooling plates are removable secured to each of the lateral members. Adjustable brackets are secured to the tooling plates and support tooling that cooperates with a workpiece supported on the tooling fixture. In one example, jack blocks, shims, squaring plates and stops are used to permit precise adjustment and repeatable relocation of the tooling in three directions.

Abstract: An actuator assembly for a welding gun is provided that has at least three positions in the example. The actuator assembly includes separate working and retract actuators. The working actuator includes a working rod movable between first and second positions. The retract actuator includes a retract rod independently movable relative to the working rod between third and fourth positions. The retract actuator is external to and non-concentrically arranged relative to the working actuator in the example shown. Actuation of the working and retract actuators is coordinated to provide at least three positions while enabling the actuators to be changed or modified independently from one another. A latching device is configured to selectively interlock the working and retract actuators to one another automatically in response to movement the working rod from the first position to the second position.

Abstract: A weld cylinder having a single piston arrangement is provided. The cylinder has a movable retract piston assembly with the piston arranged within the retract piston assembly. The piston supports a rod that is movable between home, intermediate, work, and advanced work positions. The rod moves rapidly from the home position to the intermediate position however, the rod moves more slowly from the intermediate position to the work position to reduce the impact force. A cushion chamber slowly exhausts through a pre-orifice and a hole in the cushion valve while an isolator is in an open position. Once the cushion valve opens in response to a retract-forward pressure on the cushion valve, the cushion chamber exhausts rapidly so that weld force increases rapidly to minimize increases in cycle time. Advance of a retract piston assembly is also cushioned. A weld-forward port is no longer provided on a cylinder barrel.

Abstract: A weld cylinder having a dual piston arrangement is provided. The cylinder has a movable retract piston assembly with the piston arranged within the retract piston assembly. The piston supports a rod that is movable between home, intermediate, work, and advanced work positions. The rod moves rapidly from the home position to the intermediate position however, the rod moves more slowly from the intermediate position to the work position to reduce the impact force. A cushion chamber slowly exhausts through a hole in the cushion valve while an isolator is in an open position. Once the cushion valve opens in response to a weld-forward pressure on the cushion valve, the cushion chamber exhausts rapidly so that weld force increases rapidly to minimize increases in cycle time.

Abstract: A weld cylinder having a single piston arrangement is provided. The cylinder has a movable retract piston assembly with the piston arranged within the retract piston assembly. The piston supports a rod that is movable between home, intermediate, work, and advanced work positions. The rod moves rapidly from the home position to the intermediate position however, the rod moves more slowly from the intermediate position to the work position to reduce the impact force. A cushion chamber slowly exhausts through a hole in the cushion valve while an isolator is in an open position. Once the cushion valve opens in response to a weld-forward pressure on the cushion valve, the cushion chamber exhausts rapidly so that weld force increases rapidly to minimize increases in cycle time.

Abstract: A cold spray nozzle assembly includes a venturi having converging and diverging portions interconnected at a throat. An air supply conduit is in communication with the venturi for supplying a carrier gas to the converging portion. A powder feed tube is in communication with the venturi for supplying a powder material. An adjustment member is arranged within the venturi and is axially moveable relative thereto between multiple positions. The multiple positions respectively provide multiple different areas or throat clearances including a desired area between the adjustment member and the venturi or throat clearance. As a result, the adjustment member can be axially positioned to achieve desired gas pressures, deposition rates, and accommodate machining tolerances and component wear based upon the selected area. A retention member maintains the adjustment member in the desired position during operation of the cold spray nozzle assembly.