Abstract: Apparatus is presented herein for controlling a stud welding gun for welding a stud to a workpiece. The stud welding gun has a gun body and a gun shaft mounted to the body in such a manner to permit reciprocal movement of the shaft relative to the body. The shaft has a distal end having means for carrying a stud to be welded to the workpiece. A linear motor is carried by the gun for directly driving the shaft in forward and reverse directions between fully extended and fully retracted positions relative to the gun body. A floating point detector provides a control signal when the stud engages the workpiece as the shaft is being driven in a forward direction to establish a reference position of the gun body relative to the workpiece.

Abstract: Apparatus is presented herein for controlling a stud welding gun for welding a stud to a workpiece. The stud welding gun has a gun body and a gun shaft mounted to the body in such a manner to permit reciprocal movement of the shaft relative to the body. The shaft has a distal end having means for carrying a stud to be welded to the workpiece. A linear motor is carried by the gun for directly driving the shaft in forward and reverse directions between fully extended and fully retracted positions relative to the gun body. A floating point detector provides a control signal when the stud engages the workpiece as the shaft is being driven in a forward direction to establish a reference position of the gun body relative to the workpiece.

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.

Abstract: Method and apparatus for securing abrasion resistant members to metallic surfaces to line the metallic surfaces for protection against wear is disclosed. The abrasion resistant members include an aperture therein having a taper in the bottom of the aperture. An end weldable stud of length less than the thickness of the abrasion resistant member is welded through the aperture to the metallic surface to be lined. A cup shaped spring retainer clip having side walls of dimension greater than the aperture and a stud engaging aperture of dimension less than the diameter of the stud is driven over the stud through the aperture of the abrasion resistant member into engagement with the taper of the aperture of the abrasion resistant member to draw the abrasion resistant member into firm securement with the metallic surface. An abrasion resistant plug is secured within the aperture of the abrasion resistant member following installation.

Abstract: The present disclosure is for improvements to metallic refractory anchors heretofore in use which are of a general S type configuration and which are welded to metallic walls of vessels to secure in place refractory insulation of a high abrasion resistance. The improvements consist of reforming the weld end of the S anchor in a manner to reduce the length to width ratio of the weld end to approximately no greater than 6 to 1 to permit stud welding of the anchor by the stud end welding technique. Additional metallic members are resistance welded to the weld end of the anchor to decrease the length to width ratio to within the range capable of stud welding. The additional metallic members may be formed of separate members or by extended legs of the metal anchor folded back onto a weld projection and resistance welded in place.

Abstract: Stick and stud welding apparatus which utilizes a microprocessor and related RAMs, ROMs and peripheral interface devices to control the welding parameters. The ideal desired weld current and weld cycles in the case of stud welding can be selected depending upon the mode of operation and/or stud conditions. The program for the microprocessor instructs the microprocessor to periodically compare the actual welding current to the ideal current, compute the difference and alter the phase firing time of an SCR bridge to compensate or adjust the welding current to the ideal current. In the case of stud welding mode, the program further instructs the microprocessor to reference the selected number of cycles, compute the total energy delivered across the stud and workpiece gap from actual current, welding terminal voltage and time and enlarge the number of actual weld cycles to a given percentage of that initially selected to provide a total energy input to the stud as selected.

Abstract: An electronic control unit is disclosed for a stud welding device having a movable electrode mounted on a solenoid armature, for moving the electrode away from the workpiece. The control includes a timing circuit providing a plurality of timer outputs in accordance with the preselected time intervals. A pilot arc circuit and an electrode movement circuit connected to the solenoid are activated by a timer output for establishing a pilot arc between the electrode and the workpiece and for moving the electrode from the workpiece. A welding power circuit is activated by another one of the plurality of timer outputs to establish welding current between the electrode and the workpiece. The electrode movement circuit is deactivated by another one of the plurality of timer outputs to enable the electrode to contact the workpiece by the urging of a spring. Means are provided for terminating the welding current. The control is suitable for use in a direct current welding power circuit.

Abstract: A capacitance discharge stud welding apparatus which comprises a housing. A coil is positioned in the housing and an armature is located within the coil and is movable between first and second positions relative to the coil. A stud chuck is provided for the purpose of holding a stud and is connected to the armature for movement therewith. A relatively light spring constantly urges the armature and the stud chuck toward the first position of the armature in the direction of a metal member to which a stud held by the chuck is to be welded. Engagement of the stud held by the chuck with a metal member causes the armature to move to the second position relative to the coil and against the urging of the light spring. An electrical welding current circuit is provided and electrical connection means connect the welding current circuit to the chuck and to a stud held thereby.