Abstract: A projection coined onto a metal sheet, preferably an aluminum sheet, for projection welding the sheet to an adjacent metal sheet. The projection has a thickness greater than the thickness of the sheet on which it is formed. The wall of the projection surrounds a first recess and a second recess is formed in a side of the sheet opposite the projection from which the metal cold flows to form the projection. A welding gun assembly having an improved low interia, fast response to the collapse of the projection welding the sheet having the projection to the adjacent sheet.

Abstract: A projection coined onto a metal sheet, preferably an aluminum sheet, for projection welding the sheet to an adjacent metal sheet. The projection has a thickness greater than the thickness of the sheet on which it is formed. The wall of the projection surrounds a first recess and a second recess is formed in a side of the sheet opposite the projection from which the metal cold flows to form the projection. A welding gun assembly having an improved low interia, fast response to the collapse of the projection welding the sheet having the projection to the adjacent sheet.

Abstract: A projection coined onto a metal sheet, preferably an aluminum sheet, for projection welding the sheet to an adjacent metal sheet. The projection has a thickness greater than the thickness of the sheet on which it is formed. The wall of the projection surrounds a first recess and a second recess is formed in a side of the sheet opposite the projection from which the metal cold flows to form the projection. A welding gun assembly having an improved low interia, fast response to the collapse of the projection welding the sheet having the projection to the adjacent sheet.

Abstract: A seam welding apparatus having an improved bearing support arrangement for the transversely movable upper weld wheel. This upper weld wheel is nonrotatably secured adjacent one end of an elongate electrically conductive shaft, which shaft adjacent its other end is supported within a conventional electrically conductive bearing assembly which rotatably supports the shaft and transmits electrical energy thereto from an external source such as a transformer. The nonrotatable housing associated with the bearing assembly is pivotally supported relative to the machine frame by a pivot which extends adjacent the housing in perpendicular relation to the shaft axis, with this pivot axis being disposed remote from the weld wheel. A welding force generating assembly such as a pressure cylinder and ram are mounted on the machine frame, with the ram being movably supported and acting downwardly onto a spring unit which has an electrical insulator associated therewith.

Abstract: A projection coined onto a metal sheet, preferably an aluminum sheet, for projection welding the sheet to an adjacent metal sheet. The projection has a thickness greater than the thickness of the sheet on which it is formed. The wall of the projection surrounds a first recess and a second recess is formed in a side of the sheet opposite the projection from which the metal cold flows to form the projection. A welding gun assembly having an improved low interia, fast response to the collapse of the projection welding the sheet having the projection to the adjacent sheet.

Abstract: A projection coined onto a metal sheet, preferably an aluminum sheet, for projection welding the sheet to an adjacent metal sheet. The projection has a thickness greater than the thickness of the sheet on which it is formed. The wall of the projection surrounds a first recess and a second recess is formed in a side of the sheet opposite the projection from which the metal cold flows to form the projection. A welding gun assembly having an improved low interia, fast response to the collapse of the projection welding the sheet having the projection to the adjacent sheet.

Abstract: A process and apparatus for projection welding of overlapping nonferrous sheets, particularly thin aluminum sheets. One of the sheets is provided with a projection therein, and the sheets are positioned so that the tip of the projection contacts a surface of the other sheet. The sheets are not subjected to surface pretreatment to remove the surface oxides therefrom. A projection welding head assembly is positioned with the electrode thereof engaged with one of the sheets, and the other sheet is positioned against a stationary backup or electrode. The electrode of the welding head imposes, in rapid time succession, a series of welding pulses to the overlapping contacting sheets. The series of welding pulses includes two and preferably three pulses which progressively step up in amperage to provide for precise control of the heating of the projection and the associated contact area on the other sheet to cause heating to the plastic state, and then forging (i.e.

Abstract: An integrated projection welding head and drive assembly which has a pressure drive device moving an electrode head assembly into contact with one of the workpieces projection weld two workpieces together. A force generation unit biasing the electrode assembly outwardly of the drive device is housed in the drive device.

Abstract: A process and apparatus for effecting preheating of elongate metal parts, such as bars, for permitting subsequent deformative processing of the bar. Electrode-type clamps are attached adjacent opposite ends of the elongate bar, and direct-current electricity is applied to the clamps for transmission longitudinally of the bar to effect heating thereof. A further pair of electrode-type clamps is applied directly at each free end of the bar, with the electrode clamps of each end pair being disposed for engagement on opposite sides of the bar substantially flush with the end face of the bar. An electric current, such as an alternating-current, is applied across the sidewardly-spaced electrode clamps of each end pair to effect transmission of electrical current transversely across the bar in the direct vicinity of the end face to effect additional heating directly at the end of the bar to supplement the heating which is effected by the direct-current passed longitudinally through the bar.

Abstract: A welding head for projection welding wherein the spring which biases the electrode is initially preloaded to exert a significant biasing force on the electrode to maintain it against a stop to define the normal fully extended position of the electrode. The spring of the welding head is also initially precalibrated to exert an accurate predetermined biasing force on the electrode when the electrode is depressed inwardly so as to effect compression of the spring by a predetermined distance, which latter distance is of very small magnitude. The welding head is disposed in engagement with overlapping sheets so that the electrode is engaged with the sheets in alignment with a projection thereon, and the electrode is depressed through said predetermined distance so that a uniform predetermined biasing force is applied to the electrode and hence to the projection weld area.

Abstract: A cantilevered-shaft type roller conveyor in which roller units are cantilevered inwardly from side frames. Each roller unit includes a sleevelike roller member supported directly on and surrounding a drive member, the latter being rotatably supported on a cantilevered shaft which is secured to and projects inwardly from the side frame. The drive member has a bevel drive gear which is fixedly and integrally formed on an inner free end thereof, which drive gear is driven from a mating bevel gear secured to a rotatable line shaft which is positioned inside the respective side frame and extends longitudinally of the conveyor. The drive member is preferably constructed of a suitable bearing material, such as sintered metal, to function both as a driving member and as a bearing to permit direct rotatable support of the sleeve roller member.

Abstract: A control system for a power driven conveyor line having power driven conveyor zones adjoined end to end. Each conveyor zone includes a single drive motor, a transmission, driven conveying elements extending the length of the conveyor zone, and an adjacent workstation having a designated stopping point located therein. The control system includes a local controller for controlling the operation of one or more conveyor zones via remote command signals, a respective zone controller associated with each conveyor zone for controlling the operation of the conveyor zone in response to the remote command signals, and first and second sensors coupled to each zone controller for detecting different load positions along the conveyor zone. The first sensor detects the load which causes the zone controller to linearly decelerate the motor, and necessarily the load, from a first speed to a second speed.

Abstract: A stop mechanism mountable on a powered conveyor, such as a conveyor having continuously-driven drive rollers which support and drivingly move loads such as pallets. The stop mechanism is mounted directly under and between sidewardly-spaced drive rollers to permit use of through shafts between sidewardly-spaced pairs of drive rollers. The stop mechanism has a vertically-oriented stop lever which projects upwardly for contacting a moving load, which contact effects limited vertical swinging of the lever into engagement with a fixed stop. The lever is coupled to a hydraulic shock absorber which effects rapid deceleration of the load to cause cushioned contact thereof with the fixed stop. The shock absorber preferably has an internal orifice arrangement associated with a pressure chamber which results in the orifice flow area progressively decreasing as the stop lever is moved by the load to provide more optimum control over liquid pressure and control over the resistance force imposed against the load.

Abstract: An electroplating apparatus having a tank containing a bath of an electrolytic solution, and a roll supported for immersion into the electrolytic bath for transporting a sheet material through the bath. The roll has a current collector rotatably supported on a shaft thereof for transmitting high amperage electricity to the roll. The current collector is supported on a part of the shaft which projects exteriorly of the tank side wall, and incorporates a sleevelike housing structure which surrounds and is rotatable relative to the shaft and mounts therein a plurality of conductive shoes which are of a highly electrically conductive material and are spring urged for snug radial contact with a conductive ring secured to a conductive sleeve arrangement which snugly axially and nonrotatably mounts to the shaft. The housing cooperates with the sleeve arrangement to define a generally sealed interior annular chamber in which the current-conducting shoes are positioned.

Abstract: A pair of sheets are supported on a support assembly having skewed support rollers disposed on opposite sides of an elongate guide having a pair of sidewardly opening and vertically overlapping guide grooves. The pair of sheets are disposed on opposite sides of the guide and are urged inwardly into the guide grooves so that adjacent edges of the sheets are vertically overlapped. A shuttle moves the overlapping pair of sheets toward the nip of a weld roller assembly, with the sheets being engaged by driving skewed rollers disposed directly adjacent the weld roller assembly. The sheets are drivingly moved through the nip of the weld roller assembly, with the weld roller assembly having upper and lower weld rollers which pressingly and drivingly engage the overlapping edges of the sheets therebetween to create a seam weld as the sheets move through the nip.

Abstract: A pair of sheetlike members are supported on a pair of support tables disposed on opposite sides of a movable splicing mechanism. The pair of sheets are advanced inwardly from opposite directions into a splicing position wherein the adjacent edge portions of the sheets overlap, and are suitably secured by side clamp mechanisms. The movable splicing mechanism is then linearly moved along the overlapping edges, and opposed weld rolls rollingly and clampingly engage the overlapping edges therebetween to effect welding thereof. A pair of planishing rolls rollingly and compressingly engage the seam weld and follow along behind the weld rolls to effect flattening of the seam weld. After the splicing mechanism moves along the entire length of the overlapping edges to create a mash seam weld between, a gripper mounted on the mechanism engages opposite sides of the sheet, and the mechanism then returns to its original position and simultaneously discharges the spliced sheet forwardly of the apparatus.

Abstract: A method and apparatus for creating a circumferential seam weld in surrounding relationship to a cylindrical workpiece. The workpiece is moved continuously along a work path at a preselected velocity, and is simultaneously supported for free rotation about its longitudinal central axis. The workpiece moves into engagement with opposed surfaces defined by a pair of electrodes, one of which moves relative to the other and relative to the workpiece for causing rotation of the workpiece through approximately one-half revolution, whereby the two electrodes simultaneously form two welds which are about 180.degree. apart and which may individually extend up to a total angle of rotation of about 180.degree., or slightly in excess thereof, so that the welds overlap.

Abstract: A resistance welding system having a low-inertia movable welding head coupled to a stationary welding transformer which is of low mutual reactance. Through an appropriate timing circuit and control, a high-energy pulse of current, of very short time duration, is transmitted through the welding transformer to the movable welding head. The welding head, which contacts a projection on overlapping components, effects a rapid welding of the components, and the welding head rapidly follows up the melting of the projection due to its low inertia.

Abstract: A transfer system having a transfer mechanism which is located directly on or adjacent the production machine. The transfer mechanism comprises a reciprocating workpiece shuttle driven by a hydraulic driving unit, specifically a hydraulic transfer cylinder. The latter is connected to a remote hydraulic cycloidal drive unit by long conduits which may be positioned overhead. The remote hydraulic cycloidal drive unit employs a pumping cylinder having an elongated stationary piston rod on which the cylinder housing is slidably supported, with the pressure fluid from the pumping cylinder being supplied through the conduits to the transfer cylinder. The housing of the pumping cylinder is reciprocated by a crank associated with a cycloidal mechanical drive. This crank is connected to and rotates with a gear which is rotatably supported on a slide and reacts with a stationary rack so that reciprocation of the slide causes alternate rotation of the gear.

Abstract: A rotatable member is mounted through substantially normal bearing structure onto a shaft in rotating relationship therewith. A torque limiting drive device, such as a spirally coiled spring, is fitted between the rotatable member and the shaft for permitting transmission of torque therebetween. The spring permits only a limited torque to be transmitted between the rotatable member and the shaft such that, if this torque is exceeded, then the spring slips with respect to the rotatable member to thereby permit relative rotation between the shaft and the rotatable member.