Abstract: An extruder and electrode assemblage for interconnecting the upstanding lugs of plate straps connected to the positive and negative grids of battery cell units through apertures provided in partitions, separating the cell units of a battery from each other. The electrode assemblage not only clamps the lugs against the partition but defines apertures for the extruding plungers to engage the lugs and extrude same into the partition aperture. Once the extruded lug portions contact each other, welding current is supplied thereto in a semi-annular path by the electrodes.

Abstract: Self-equalizing welding structure and method. The structure comprises piston and cylinder structure held in a fixed support, including cylinder ends movable into and out of the opposite ends thereof, a welding electrode attached to one rod cylinder end on one side of a workpiece, a travel rod extending through the support and connected to the other cylinder end, means for securing a second electrode to the travel rod on the other side of the workpiece, and self-equalizing pressure means for extending the cylinder ends from the piston and cylinder structure and for withdrawing them into the piston and cylinder structure.

Abstract: A three-dimensional composite structural panel composed of a number of parallel trusses mutually spaced by interposed insulative elements and interconnected by cross wires, is fabricated by positioning a cross wire transversely of the longitudinal runner wires of trusses after they are stacked in alternation with the insulative elements, and then welding the cross wire to the runner wires at each point of contact. Rows of electrodes, one for each side of the lattice, are mounted to simultaneously resistance weld a single cross wire at each side of the lattice to all of the trusses of a panel. All of the electrodes are pressed against the wires to be welded by means of individual fluid motors energized with a common fluid pressure and separately driving individual electrodes.

Abstract: In effecting resistance welding, fluid pressure is applied to a piston in a cylinder to drive the piston rod ahead so that work being welded is clamped between an electrode provided at the end of the rod and another electrode carried by an arm to apply a suitable welding pressure to the work. As the piston is further moved ahead, a collector ring is expanded radially outwardly to make electrical contact with the power feeding liner, so that welding current fed from a feeder cable is supplied to the electrode through the cylinder, feeding liner, collector ring, collector plate and the rod, thereby to effect the welding while applying a suitable pressure to the work.

Abstract: Means are shown for carrying current within the moving members of a reciprocable fluid motor such as is used to operate a welding gun. The current is transmitted from a cable to the piston rod through a stationary contactor having a portion secured to the cylinder housing and circumferentially arranged leaves held by a spring against the piston rod surface. The seal construction is such as to permit the use of lubricants on the sliding contact surface and at the same time prevent cooling water for entering the lubricating reservoir. The external contactor permits use of a hollow type piston rod allowing cooling water to be carried therethrough if desired. When used for welding gun applications the invention eliminates the need for flexible type shunts and separate electrode holders along with flexible water hoses in the welding area. The invention may also be utilized for lower power applications such as sensing devices.

Abstract: A resistance welder is disclosed which provides the same current at the welding electrodes as comparable resistance welders while requiring less input current. The surprising efficiency of the novel resistance welder permits it to accommodate wide workpieces in a deep throat. The increased demand for power to the welding electrodes, which demand results from the deep throat, is satisfied by the surprising efficiency of the combination of elements utilized in the invention. This invention combines linear transformers, having secondary terminals at extreme linear ends of the transformers, which linear transformers function as part of at least one body member of the welder to provide unexpected efficiency. These uniquely placed linear transformers minimize throat inductance and reduce energy consumption.

Abstract: A C-shaped spot welding gun has its movable electrode extending from one arm of the gun's C-yoke. An air cylinder for moving the electrode is attached on the opposite side of the arm. A package of parallel copper strips is bent to U-shape and surrounds the arm below the air cylinder. One end of the U-shaped flexible conductor thus formed is attached to a fixed current connection member on one side of said arm, whereas the other conductor end is attached to a movable current connection member slidable in a guide on an opposite, parallel side of the arm. The movable current connection member is carried by the moving electrode by means of current conducting coolant pipes.

Abstract: An electrical resistance welding apparatus for making an integral and homogeneous connection between a terminal and a battery lug accomplished by limiting the area of contact between the two as by equipping the battery with an insulation card which is at least partially disposed between the lug and the terminal. The apparatus presses a portion of the overlapping area of the lug through an opening in the insulation card to make contact over a relatively small area with the terminal by first moving one electrode to contact the terminal and then moving the remaining electrode to contact the lug. The electrode assemblies clamp the lug and terminal together. Current is provided to the electrodes to heat up the area of contact as it is made, thereby melting the lead in the opening in the insulation card. As the lug and terminal are continuously squeezed together, more cold lead flows into the opening where the fusion is taking place.

Abstract: A resistance welding electrode is formed of a hollow shank carrying current and cooling fluid and an electrode head connected to the shank by a flexible housing of insulated material. The housing forms a chamber to contain the cooling fluid supplied through the shank. The flexibility of the housing allows the head to rock relative to the shank and also to move axially away from the shank under the influence of the pressure of the cooling fluid. When welding pressure is applied through the electrode to a workpiece, the shank is forced against the head to provide firm electrical engagement between those elements.

Abstract: Apparatus and controls are provided for resistance welding one workpiece or body to another. A movable electrode is driven by a cylinder and a piston which are positioned in tandem with a second cylinder and a second piston. The design enables a small pressure applied to the second piston to result in a large force applied by the electrode to the bodies to be welded, with a back-up electrode located on the opposite side of the bodies. Controls for the apparatus enable the force applied by the movable electrode to the bodies to be changed almost instantaneously so that the force applied can be raised and lowered during the actual resistance welding cycle. In some intances, by way of illustration, the pressure is raised while the welding current is on, and, in other instances, the force is decreased and then increased again during the welding cycle.

Abstract: Resistance welding apparatus having a power driven welding head carrying a first welding electrode for co-operation with a second welding electrode, wherein the head is switched from a low-force approach operating mode to a high-force squeeze operating mode only when the welding electrodes electrically contact one another, either directly or through a workpiece therebetween, so that no gap exists in which an operator's hand or finger can be crushed between the electrodes upon transition from low-force to high-force operation.

Abstract: A pneumatically operated welding machine particularly useful for welding small diameter wires onto pins for electronic circuitry is described. In such welding an insulated wire is fed through a hollow upper electrode for welding between the electrode and a pin. Equal pressures applied by the upper and lower electrodes first exert sufficient force for penetrating the plastic insulation and thereafter the force is reduced to an optimum level for welding. The upper and lower electrodes are connected to double acting pneumatic cylinders connected to a pneumatic circuit that sequentially brings the electrodes into light contact with the workpiece for lateral positioning, applies sufficient breakthrough force to penetrate the plastic insulation, applies a reduced force during a welding period and finally retracts the electrodes.