Abstract: A stud welding system which utilizes a stud welding gun capable of interacting with the stud welding power supply and welding controller in a manner such that the extent and rate of lift, duration of holding and lift position and extent and rate of plunge can be independently varied and controlled over a wide range. The interactive stud welding gun utilizes a stepping motor in the stud welding gun which actuates the gun shaft assembly and its associated chuck carrying the stud to be welded. A transducer associated with the stud welding gun senses the position of the gun shaft assembly relative to the gun body and provides a reference signal therefor. A microprocessor controlled interactive gun control responds to the signal from the tranducer to determine gun shaft assembly position and generates an energization signal for the stepping motor to drive the gun shaft between lift, hold and plunge positions preprogrammed into the interactive gun control.

Abstract: A multi-operator grid system for stud welding is disclosed which works in conjunction with a microprocessor controlled single stud welding power supply. The multi-operator grid system utilizes a single multiplexer interconnected with a plurality of weld stations each of which includes an isolator, hand held terminal and stud welding gun. Each hand held terminal working through the multiplexer can program the microprocessor stud welding supply for parameters of pilot arc and welding current energy and cycles. The microprocessor controlled stud welding supply, through the multiplexer, provides read outs to printers and to the hand held terminals of the resultant stud welding parameters such as total welding energy, weld current and the like. The multiplexer, working in conjuction with the microprocessor controlled stud welding supply and the isolators, controls the pilot arc and weld current to the stud welding guns as well as the plunge thereof.