Abstract: A fishing rod and lure system for collecting and analyzing fishing data to provide for manual or automatically controlled fishing experience comprising a fishing rod having a handle portion and a shaft portion, a fishing line reel encasing fishing line, a plurality of guides located along the fishing rod for guiding the fishing line, a lure attached to the fishing line, a central control device electrically coupled with the fishing rod for receiving, manipulating and outputting data and configured to control the lure, a display device electrically coupled with the central data device and capable of receiving and displaying data, and a sensor electrically coupled with the central control device for sensing and sending data to the central control device, wherein the central control device uses the data received from the sensor to display data to the user via the display and control the fishing rod and lure system.

Abstract: A welding method and system for welding a workpiece at weld locations includes a weld controller having control logic and stored data related to weld locations and workpiece dimensions. The weld controller is operable with a displacement sensor for monitoring the displacement between the electrodes of a weld gun. The control logic is programmed to generate a move signal based upon the stored data and the displacement between the electrodes. The weld controller also has stored data related to primary and alternate weld locations. The control logic is programmed to generate a fault signal based upon the stored data and a welding parameter such as the displacement between the electrodes. The weld controller provides a fault signal to the position controller to index the weld gun from a primary weld location to an alternate weld location when a comparison of the welding parameter to stored data related to the primary weld location indicates that the workpiece has been improperly welded.

Abstract: A clinching station for securing a first workpiece to a second workpiece includes control logic receiving a punch position sensor output and processing the punch position sensor output and an established position signature to generate a clinching operation status signal. The clinching station includes a punch and die assembly including a punch and a die mounted opposite each other for movement relative to each other along a working axis. A position sensor is configured to monitor the position of the punch relative to the die, and has an output indicative of the position of the punch relative to the die. The established position signature corresponds to an acceptable clinching operation, and allows the control logic to generate the clinching operation status signal.

Abstract: A welding system for real-time weld quality detection during resistance welding of a workpiece has a sensor assembly including a winding and a core mounted generally coaxially within the cylinder of the welding gun. A piston and piston rod assembly are mounted for coaxial movement within the cylinder. The piston rod has an end protruding from the cylinder for affixing an electrode thereto. Axial movement of the piston rod relative to the cylinder causes axial movement of the core relative to the winding to vary a length of core and winding overlap. The sensor assembly produces an output signal based on the length of core and winding overlap to indicate piston rod position relative to the cylinder. Weld control logic receiving the sensor assembly output controls welding of the workpiece in real-time.

Abstract: An apparatus and method for welding a bracket to a tube are disclosed. A bracket having a semi-cylindrical portion with an inner surface and a radially inward projection extending from the inner surface is positioned adjacent to a tube with the semi-cylindrical portion of the bracket coaxially nested about the tube and with the radially inward projection engaging the tube at a faying surface. A resistance welding apparatus having a controller, an actuator, and a power supply is then provided. The power supply is coupled to the bracket and the tube through respective electrodes. A transducer cooperates with the electrodes to provide an output indicative of the position of the electrodes. A controller cooperates with the transducer and the power supply wherein the controller regulates the power output of the power supply as a function of the displacement between the electrodes to ensure that the bracket is properly welded to the tube.

Abstract: An apparatus and method for resistance welding and then hot forging first and second workpieces together is disclosed. The first workpiece is provided with a deformable rivet. The second workpiece is provided with an aperture sized to receive the deformable rivet. The first and second workpieces are placed together with the deformable rivet of the first workpiece extending through the aperture in the second workpiece. A resistance heating power supply having a pair of power output terminals is provided. One of the terminals is connected in electrical communication with the first workpiece and the other one of the terminals is connected to a hot forging electrode. The hot forging electrode is movable relative to the deformable rivet. The hot forging electrode is affixed to an actuator. The actuator shifts the hot forging electrode into and out of engagement with the deformable rivet. A transducer provides an output indicative of the position of the hot forging electrode to determine rivet deformation.

Abstract: An apparatus and method for resistance welding tubular parts is disclosed. The apparatus includes a weld gun having displaceable electrodes with contact faces engaging the parts. The contact faces are designed to distribute the forces applied to the parts by the electrodes to prevent deformation and to hold the parts together steadily in order to minimize undesired electrode displacement. A test computer monitors the amount of electrode displacement occurring as a result of penetration of the parts into each other during welding. When the displacement between the electrodes falls within a predetermined displacement range, which is indicative of a proper weld between the parts, the computer cooperates with a weld controller to terminate the welding power, thereby inhibiting any substantial further penetration of the parts. The apparatus and method is suitable for tube-to-tube and wire-to-tube applications commonly performed in the manufacture of automobile seats.

Abstract: A system and method is disclosed for monitoring and controlling a resistance projection welder for welding a projection weld nut to a workpiece. A displacement sensor measures the displacement of a welding electrode of a weld gun in real time during the welding procedure. A computer is coupled to the displacement sensor and determines whether the projection weld nut is correctly loaded between the workpiece and the welding electrode. The computer instructs a programmable logic controller (PLC) to trigger a weld controller to apply power to the welding electrode if the projection weld nut is correctly loaded onto the workpiece. The computer instructs the PLC to inhibit power if it determines the projection weld nut to be inverted, missing, or misaligned in order to allow for the removal and replacement of the projection weld nut.

Abstract: Control systems and methods for inspecting at least one of a plurality of parts using an inspection station are disclosed. A comparator coupled to the inspection station compares a test signal responsive to a measured parameter of a part in the inspection station to a reference signal to determine if the part matches a predetermined profile. The comparator then provides a fault signal which disables the inspection station upon determining that a part matches the predetermined profile. The profile matching part is then removed from the inspection station and stored in a storage device. The storage device then provides a confirmation signal to the comparator indicating that the profile matching part has been stored in the storage device. The comparator then enables the inspection station upon receipt of the confirmation signal.

Abstract: An apparatus and method for resistance welding tubular parts. The apparatus includes a weld gun having electrodes with arcuate contact faces engaging the parts. The electrodes are displaceable relative to each other. The contact faces are designed to distribute the force applied to the parts to prevent deformation and to hold the parts together steadily in order to minimize the amount of undesired electrode displacement caused by these effects. A test computer monitors the amount of electrode displacement occurring as a result of penetration of the parts into each other during welding. When the displacement between the electrodes falls within a predetermined displacement range, which is indicative of a proper weld between the parts, the computer cooperates with a weld controller to terminate the welding power, thereby inhibiting any substantial further penetration of the parts.

Abstract: A system and method is disclosed for monitoring and controlling a resistance projection welder for welding a projection weld nut to a workpiece. A displacement sensor measures the displacement of a welding electrode of a weld gun in real time during the welding procedure. A computer is coupled to the displacement sensor and determines whether the projection weld nut is correctly loaded between the workpiece and the welding electrode. The computer instructs a programmable logic controller (PLC) to trigger a weld controller to apply power to the welding electrode if the projection weld nut is correctly loaded onto the workpiece. The computer instructs the PLC to inhibit power if it determines the projection weld nut to be inverted, missing, or misaligned in order to allow for the removal and replacement of the projection weld nut.

Abstract: A control system and method for inspection of parts is particularly adapted for inspecting resistance welded parts in a production line environment. A displacement sensor is coupled to a welding electrode for generating a displacement sensor signal responsive to the displacement of the welding electrode during welding. A test computer evaluates the displacement sensor signal to identify defective parts and to provide a fault signal. A part containment box receives the improperly welded parts and has an input sensor for generating a signal when an improperly welded part is deposited therein. The test computer is operative to disable the production line and prevent the indexing of parts until the defective part has been removed from the production line and deposited into the part containment box which generates the input sensor signal, thereby enabling the production line.

Abstract: The present invention provides a weld control monitoring system which determines the quality of the welds in real time, and provides responsive useful outputs indicating the quality of the weld. The system permits the user to input weld data as well as quality specifications which the part must meet in order to continue the production run. A monitoring system can be used with or without programmable logic controllers and includes special program for estimating the tip wear of the welding electrodes. The present invention also includes a weld gun control in which additional support for the weld gun electrode is provided by adjacent rail structures which permit displacable movement of the electrode mounted to linear displacement welding cylinder. A sensor coupled to the piston rod of the weld cylinder provides linearly variable displacement transducer signals for use in monitoring portion of the apparatus.

Abstract: A method and apparatus are disclosed for monitoring and controlling a multi-gun resistance welding apparatus. An embodiment of the system comprises a computer which executes a routine that allows supervision of the multi-gun welding system, a programmable logic controller which controls movement of the guns and gun delivery devices, gun sensors which measure the displacement of gun electrodes, delivery device sensors for determining a location of the gun delivery devices, fixture sensors for measuring the location of a workpiece fixture, a weld controller which applies power to the gun electrodes, and an analog-to-digital converter which converts the outputs of the sensors to digital signals readable by the computer. An embodiment of the weld routine executed by the computer spatially gauges the pre-weld fit-up of the workpieces and inhibits the application of weld power if the fit-up is not within a specified tolerance.

Abstract: A method and apparatus for diagnosing various faults during resistance welding based upon electrode position. An electrode positioning bracket is coupled to the electrode. The position of the bracket is measured by means of a linear variable displacement transducer. The position of the bracket is used to determine the electrode position, and in turn, electrode positioning faults, and weld quality.

Abstract: The present invention provides a weld control monitoring system which determines the quality of the welds in real time, and provides responsive useful outputs indicating the quality of the weld. The system permits the user to input weld data as well as quality specifications which the part must meet in order to continue the production run. A monitoring system can be used with or without programmable logic controllers and includes special program for estimating the tip wear of the welding electrodes. The present invention also includes a weld gun control in which additional support for the weld gun electrode is provided by adjacent rail structures which permit displacable movement of the electrode mounted to linear displacement welding cylinder. A sensor coupled to the piston rod of the weld cylinder provides linearly variable displacement transducer signals for use in monitoring portion of the apparatus.

Abstract: An assembly is provided for mounting on an end of a robot arm actuator as an integral spot resistance welding gun and transformer unit. A gun slide support bracket is connected to the transformer and serves to provide a mount for a sliding gun cylinder having a piston connected to one of the jaw electrodes. The lower jaw is removably connected to the cylinder. Roller shunts are used to provide electrical connection between secondary terminals on the transformer and the two electrodes. A proximity switch assembly is advantageously utilized to provide signals to the robot controller indicating a fully retracted position of the jaws.

Abstract: An assembly is provided for mounting on an end of a robot arm actuator as an integral spot resistance welding gun and transformer unit. A gun slide support bracket is connected to the transformer and serves to provide a mount for a sliding gun cylinder having a piston connected to one of the jaw electrodes. The lower jaw is removably connected to the cylinder. Roller shunts are used to provide electrical connection between secondary terminals on the transformer and the two electrodes. A proximity switch assembly is advantageously utilized to provide signals to the robot controller indicating a fully retracted position of the jaws.

Abstract: A method and apparatus are disclosed for detecting weld nugget growth on a workpiece during a welding operation using a resistance spot welding gun. In the preferred embodiment, a piston rod is slidably mounted in a cylinder and is connected at one end to an electrode of the gun. The opposite end of the piston rod extends rearwardly through the cylinder and is coupled to a sensor assembly for detecting the amount of movement of the piston rod created by weld nugget growth on the workpiece during the welding cycle.

Abstract: A system and method is disclosed for monitoring and controlling a resistance projection welder for welding a projection weld nut to a workpiece. A displacement sensor measures the displacement of a welding electrode of a weld gun in real time during the welding procedure. A computer is coupled to the displacement sensor and determines whether the projection weld nut is correctly loaded between the workpiece and the welding electrode. The computer instructs a programmable logic controller (PLC) to trigger a weld controller to apply power to the welding electrode if the projection weld nut is correctly loaded onto the workpiece. The computer instructs the PLC to inhibit power if it determines the projection weld nut to be inverted, missing, or misaligned in order to allow for the removal and replacement of the projection weld nut.