Abstract: A system and method of welding a workpiece. A predetermined current may be applied through electrodes that engage the workpiece. A resistance profile may be generated based on the predetermined current. A weld profile may be selected based on the resistance profile. The weld profile may then be executed to weld the workpiece.

Abstract: A method is disclosed for dressing a resistance stop welding (RSW) tip and a tip dresser apparatus. According to the method, a circumferential shoulder is cut to a predetermined depth from a distal end of the RSW tip. The shoulder is cut in the side wall to provide a reduced radius side wall and a reduced radius distal end on the RSW tip. The depth of dressing the distal end of the RSW tip is controlled by providing a stop that engages a step formed in the side wall formed by the circumferential shoulder. The tip dresser apparatus includes a first cutting blade retained by a first holder that cuts a step into the side wall to a predetermined depth. A second cutting blade retained by a second holder cuts a radiused surface on the distal end until the stop engages the step.

Abstract: A high capacity aluminum spot welding trans-gun includes a pair of opposed electrodes, a weld control that controls the operation of the trans-gun, and a transformer that regulates the voltage to the trans-gun having a primary input voltage and secondary output voltage. A liquid-cooled high voltage primary conductor electrically connects the weld control to the transformer primary input and a low voltage secondary conductor electrically connects the transformer secondary output to the welding gun to energize the opposed electrodes.

Abstract: An aluminum welding system includes a welding machine configured to weld a workpiece with an aluminum nugget and a measurement device configured to measure an attribute of at least one of the aluminum nugget and a welding process. The system further includes a processing device configured to output a weld quality signal representing a quality of an aluminum weld based at least in part on the attribute measured. A method includes measuring an attribute of at least one of an aluminum nugget forming a joint of a workpiece and a welding process, determining a quality of an aluminum weld based at least in part on the attribute measured, and outputting a weld quality signal representing the determined quality.

Abstract: A welding electrode assembly is provided including a mounting adapter, a shank and an electrode cap. The electrode assembly includes a shortened shank reinforced over a larger percentage of its length by the mounting adapter and electrode cap. Further, the cap includes a larger or longer working end allowing for the completion for more spot weld operations before requiring replacement.

Abstract: A self-piercing die riveter having an indexable die table on the nose of its frame. The die table has a number of dies disposed thereon. The frame defines a first passage and a second passage in communication with and diverging from the first passage. An actuator for indexing the die table is located on the riveter outside of the nose of the frame and is connected to the die table through either shafts or belts disposed within the first and second passages. The die table has a number of detents that cooperate with a locating arm to hinder indexing of the die table and position the dies in-line with the path of a reciprocating punch.

Abstract: A method is disclosed for dressing a resistance stop welding (RSW) tip and a tip dresser apparatus. According to the method, a circumferential shoulder is cut to a predetermined depth from a distal end of the RSW tip. The shoulder is cut in the side wall to provide a reduced radius side wall and a reduced radius distal end on the RSW tip. The depth of dressing the distal end of the RSW tip is controlled by providing a stop that engages a step formed in the side wall formed by the circumferential shoulder. The tip dresser apparatus includes a first cutting blade retained by a first holder that cuts a step into the side wall to a predetermined depth. A second cutting blade retained by a second holder cuts a radiused surface on the distal end until the stop engages the step.

Abstract: An apparatus, tool and method for clearing a rivet from an automated riveting tool. The riveting tool has a nose that supports the rivet as the rivet is installed by a punch. A clamping ring engages a work piece while installing the rivet. A clamping ring engages a block, but defines a clearance area into which the rivet is ejected when an unsuitable rivet is detected. A sensor monitors the rivets in the nose and prevents installation of the rivet when the rivet in the nose is not suitable for installation. System controls are provided to stop insertion of an unsuitable rivet while the robot continues to move the rivet tool through the complete cycle without inserting rivets until the unsuitable rivet is cleared.

Abstract: An aluminum welding system includes a welding machine configured to weld a workpiece with an aluminum nugget and a measurement device configured to measure an attribute of at least one of the aluminum nugget and a welding process. The system further includes a processing device configured to output a weld quality signal representing a quality of an aluminum weld based at least in part on the attribute measured. A method includes measuring an attribute of at least one of an aluminum nugget forming a joint of a workpiece and a welding process, determining a quality of an aluminum weld based at least in part on the attribute measured, and outputting a weld quality signal representing the determined quality.

Abstract: An electrode dresser is provided. The electrode dresser includes a face cutting segment having a top surface and a face rake surface. The top surface intersects the face rake surface and forms a face cutting edge. The face cutting edge is configured to remove deposits located on a face of an electrode. The face rake surface forms a face rake angle with a line generally perpendicular to the top surface. A side cutting segment extends from the face cutting segment and has a top surface and a side cutting surface. The top surface intersects the side cutting surface thereby forming a side cutting edge. The side cutting edge is configured to dress a distorted tapered side of an electrode tip. The side cutting surface forms a side rake angle with a line perpendicular to the top surface. The face rake angle is different from the side rake angle.

Abstract: A self-piercing die riveter having an indexable die table on the nose of its frame. The die table has a number of dies disposed thereon. The frame defines a first passage and a second passage in communication with and diverging from the first passage. An actuator for indexing the die table is located on the riveter outside of the nose of the frame and is connected to the die table through either shafts or belts disposed within the first and second passages. The die table has a number of detents that cooperate with a locating arm to hinder indexing of the die table and position the dies in-line with the path of a reciprocating punch.

Abstract: An apparatus, tool and method for clearing a rivet from an automated riveting tool. The riveting tool has a nose that supports the rivet as the rivet is installed by a punch. A clamping ring engages a work piece while installing the rivet. A clamping ring engages a block, but defines a clearance area into which the rivet is ejected when an unsuitable rivet is detected. A sensor monitors the rivets in the nose and prevents installation of the rivet when the rivet in the nose is not suitable for installation. System controls are provided to stop insertion of an unsuitable rivet while the robot continues to move the rivet tool through the complete cycle without inserting rivets until the unsuitable rivet is cleared.

Abstract: A high capacity aluminum spot welding trans-gun includes a pair of opposed electrodes, a weld control that controls the operation of the trans-gun, and a transformer that regulates the voltage to the trans-gun having a primary input voltage and secondary output voltage. A liquid-cooled high voltage primary conductor electrically connects the weld control to the transformer primary input and a low voltage secondary conductor electrically connects the transformer secondary output to the welding gun to energize the opposed electrodes.

Abstract: An electrode dresser is provided. The electrode dresser includes a face cutting segment having a top surface and a face rake surface. The top surface intersects the face rake surface and forms a face cutting edge. The face cutting edge is configured to remove deposits located on a face of an electrode. The face rake surface forms a face rake angle with a line generally perpendicular to the top surface. A side cutting segment extends from the face cutting segment and has a top surface and a side cutting surface. The top surface intersects the side cutting surface thereby forming a side cutting edge. The side cutting edge is configured to dress a distorted tapered side of an electrode tip. The side cutting surface forms a side rake angle with a line perpendicular to the top surface. The face rake angle is different from the side rake angle.

Abstract: A system and method of welding a workpiece. A predetermined current may be applied through electrodes that engage the workpiece. A resistance profile may be generated based on the predetermined current. A weld profile may be selected based on the resistance profile. The weld profile may then be executed to weld the workpiece.