Apparatus for electrical resistance spot welding

An improved welding apparatus and method of use including a pair of opposed electrodes mounted on arms which are fixed against outward displacement during the application of the welding current. One of the arms includes a pneumatic cylinder for moving an electrode to and away from the work piece. The cylinder includes a piston rod attached to a clutch by a ball screw mechanism. A brake assembly is connected to the unidirectional clutch to prevent outward displacement of the electrodes during expansion of a weld nugget and permitting inward movement of the electrodes to provide indentation of the weld after the nugget softens.

FIELD OF THE INVENTION 
Stiebel, U.S. Pat. No. 4,419,558 (Dec. 6, 1983) and A. Stiebel, C. Ulmer, 
D. Kodrack, B. Holmes, "Monitoring and Control of Spot Weld Operations," 
SAE Technical Paper Series No. 860579 (1986), Issue No. 148-7191 describe 
monitoring and controlling electrical resistance spot-welding by measuring 
displacements of the electrodes during welding. After the squeezing force 
is applied by the electrodes to the work pieces and the supply of welding 
current is initiated, the metal at the work site first expands thermally 
as it heats (expansion) and then flows plastically as it softens and fuses 
(indentation). The electrodes are displaced by the expansion and 
indentation of the metal at the weld site as well as by the expansion and 
contraction of the electrodes. Thus, measurements of the displacement of 
the electrodes during formation of the weld contain information indicative 
of the state of the metal at the weld site. 
It has long been known that moderate indentation almost always ensures a 
good weld. The ability to measure the onset of indentation makes it 
possible, therefore, to shut off the welding current upon detection of 
indentation with a high level of assurance that a good weld has been 
formed. The Stiebel patent and the Stiebel et al technical paper referred 
to above are incorporated by the foregoing reference to them into the 
present specification. 
In the method and apparatus of the Stiebel patent (and the Stiebel et al. 
technical article) consistent measurements of displacement are assured by 
interposing a mechanical compression spring between the piston of an air 
cylinder (or its equivalent) that moves the movable electrode into 
engagement with the work piece and a stationary electrode. 
A load cell associated with the spring detects the changes in the load 
imposed on the spring as the movable electrode is displaced upon expansion 
and indentation of the metal of the work pieces at the weld site during 
formation of the weld. Compressing the spring during expansion provides 
changes in the resulting forces in the spring and thus on the load cells 
that are directly proportional to the displacement of the movable 
electrode. Without the spring, for example with a hydraulic or pneumatic 
cylinder directly working on the movable electrode, the piston is 
theoretically free to displace with the movable electrode in direct 
correspondence with the electrode movements, this providing no change in 
load and no opportunity to detect electrode displacements by detection of 
load changes. 
SUMMARY OF THE INVENTION 
It has been discovered that greatly improved welding characteristics may be 
had by fixing the electrodes in position against outward displacement when 
the metal work pieces expand during the application of welding current and 
permitting inward displacement of the electrodes after the softening of 
the metal nugget. Disclosed is a welding apparatus having a frame 
supporting a pair of arms having welding electrodes. At least one of the 
pair of arms is connected to a pneumatic cylinder operable for moving an 
electrode against a work piece and placing a squeezing force by the 
electrodes on the work piece. 
Air pressure is supplied to the cylinder during the welding cycle to 
maintain the squeezing force on the work piece. The squeezing force is 
opposed by a counterforce of the metal work pieces. 
The pneumatic cylinder includes a brake for preventing an outward 
displacement of electrodes during thermal expansion of the weld nugget. 
The brake includes a plurality of wedges which are disposed in an axial 
bore within the piston rod and movable outwardly to frictionally engage 
the inner surface of the axial bore of the piston rod. 
The frictional force of the brake is controlled to be equal or slightly 
greater than the expansion force of the weld nugget to hold the cylinder 
against outward displacement during expansion of the weld nugget. However, 
after the metal softens, the counterforce of the metal is reduced so that 
the squeezing force is greater than the counterforce of the nugget and 
frictional force of the brake to permit the electrode to travel inwardly 
to form indentation. 
A first alternative preferred embodiment of the invention is also 
disclosed. The first alternative embodiment includes a pneumatic cylinder 
having an electrically operated brake. A ball screw assembly connects a 
unidirectional clutch and a piston rod. The piston rod is connected to at 
least one of the electrodes. The brake assembly is operable with the 
unidirectional clutch to lock the electrodes against outward displacement 
during the weld cycle. However, the unidirectional clutch and ball screw 
assembly permit the piston rod and electrode to move inwardly after the 
metal of the work piece softens to cause indentation. 
A second alternative embodiment is also disclosed. The second alternative 
embodiment includes a pneumatic cylinder having a piston rod having a 
working end extending from one end of the cylinder and a rod extension 
with friction pads extending from a cylinder cap on an opposite end of the 
cylinder. A brake assembly is movably mounted to the cylinder cap on a 
pair of pins. The brake assembly is spring-biased away from the cylinder. 
The brake assembly has self-centering apparatus provided to permit the 
brake assembly to frictionally engage the friction pads of the rod 
extension to lock the rod against outward movement during expansion of the 
weld nugget. The pins and springs permit inward movement of the piston rod 
and electrode after the metal of the work piece is softened. 
The apparatus of the invention provides a weld with greatly improved 
welding characteristics. By locking the electrodes in position against 
expansion during the application of welding current, there is a reduction 
in sparking and resulting spark expulsion of the weld nugget. 
Additionally, the fixing of the electrodes against outward displacement 
results in increased pressure being applied to the weld nugget as a result 
of the expansion of the nugget during the application of the weld current. 
This increased pressure results in an improved weld. The apparatus also 
permits proper indentation of the nugget after softening of the metal. 
Additionally, the apparatus is advantageously used in conjunction with 
piezoelectric strain gauges for controlling weld current, as disclosed in 
co-pending patent application Ser. No. 694,937, now U.S. Pat. No. 
5,111,020.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
Shown in FIG. 1 is an embodiment of a welding apparatus 10 embodying the 
invention of a type for use in the welding of a work piece 12, by 
electrodes 42 and 54. The welding apparatus shown is particularly suitable 
for welding car and truck bodies. The welding apparatus 10 has a rigid 
frame 14 including flanges 16 extending along one side of the frame. Each 
flange 16 has a bore 18 for accepting a fastener to secure the frame to a 
robotic arm (not shown) which is used to position the welding apparatus. 
The frame may be secured to a machine or by an independent hanger. 
Mounted to a top surface 20 of the frame 14 is a pressure equalizing device 
including a slide bar 26 an inner arm 32 and an outer arm 34 for use in 
balancing the pressure exerted on the work piece by the electrodes 42 and 
54. The slide bar 26 is reciprocally movable on a pair of rails 28 along 
the top surface 20 of the frame 14. A biasing member 22 such as a spring 
or pneumatic cylinder, is connected by a threaded rod 24 to the slide bar 
26 to force the slide bar in the direction of the work piece 12. 
As shown in FIG. 1, the inner arm 32 and an outer arm 34 are fixedly 
mounted to the slide bar 26. The outer arm 34 includes a mounting bracket 
36 having an elongated portion 37 mounted to the slide bar 26. Extending 
from a free end of the mounting bracket 36 is an L-shaped member 38 
supporting a conventional electrode holder 40 and the electrode 42. 
Electrical current is delivered to the electrode 42 by conductive material 
disposed within the electrode holder 40 and L-shaped member 38. Electrical 
current is carried from a supply of electrical power carried at the frame 
by an extension bar 43 and wire 44. The wire 44 is flexible to facilitate 
movement of the outer arm 34. The electrode holder 40 is removable from 
the L-shaped member 38 by rotating threaded locking members 46. 
As best shown in FIG. 1, the inner arm 32 includes a pneumatic cylinder 48 
having a piston rod 50 supporting an electrode holder 52 and the electrode 
54. The pneumatic cylinder 48 is bolted to elongated portion 37 of the 
mounting bracket 36. 
When pressurized, the pneumatic cylinder 48 is operable to extend the 
piston rod 50 and the electrode 54 to contact the work piece 12. The 
cylinder is pressurized sufficiently to overcome the force of the biasing 
member 22, to move the slide bar away from the work piece and draw the 
electrode 42 to the work piece and place a predetermined squeezing force 
on the work piece. The squeezing force is sufficient to hold the 
electrodes firmly in contact with the work pieces but not so great as to 
deform the electrodes or work piece. The force varies according to the 
composition of the material of the work piece and electrodes. The slide 
bar and spring permit equalization of the pressure put on the sides of the 
work piece by the electrodes 42, 54. 
As best shown in FIG. 3, the pneumatic cylinder 48 includes a cylinder 
barrel 56 having an end piece 58 at one end and a cap 62 at the opposite 
end. The piston rod 50 extends through a bore 60 in the end piece 58 and a 
bore 64 in a center port member 66 to a main piston 68. An auxiliary 
piston 70 is mounted to the piston rod to move within the barrel between 
the center port member 66 and end piece 58. The main piston 68 and 
auxiliary piston 70 each have annular grooves containing O-rings 71 to 
provide a seal with the interior surface of the barrel 56. 
A primary port member 72 is mounted between the center port member and cap. 
The primary port member 72 has a forward stroke port P.sub.1 and the 
center port member has a forward stroke port P.sub.2. The forward stroke 
ports (P.sub.1 and P.sub.2) are connected to a source of pressurized 
fluid, such as compressed air (not shown). When compressed air is 
introduced into the cylinder through P.sub.1 and P.sub.2. The main piston 
68 and auxiliary piston 70 are forced to move the piston rod and electrode 
54 in a direction shown by Arrow A in FIG. 4 forward towards the work 
piece 12. The center port member 66 has a port P.sub.3 for introduction of 
pressurized air into the barrel to act on the main piston 68 to return the 
piston rod 50 from the work piece in a direction shown by Arrow B of FIG. 
6. 
As shown in FIGS. 3, 4 and 6, the piston rod 50 has an axial bore 74 
extending from the end piston 68 to the center piston 70. Disposed within 
the bore 74 is a brake rod 76 supporting a cylindrical spacer 78 and brake 
wedges 80 for mechanically locking the piston rod in position. One end of 
the spacer 78 is fixedly mounted within a bore of the primary port member 
72. An axial throughbore extends through the spacer 78 and primary port 
member 72 and brake wedges 80 for slidingly accepting the brake rod 76. 
A frusto-conical mandrel 82 is attached at one end of the brake rod 
adjacent the brake wedges 80. A brake piston 84 is attached to the 
opposite end of the brake rod 76. The brake piston 84 is disposed in the 
cylinder barrel between the primary port member 72 and cap 62 and has an 
O-ring 86 disposed in an annular groove, as best shown in FIGS. 5 and 6. 
The brake piston 84 is displaceably away from the primary port member 72 
by compressed air received through port P.sub.4. Movement of the brake 
piston 84 away from the primary port member 72 results in the movement of 
the piston rod and brake mandrel 82 in the direction shown by Arrow B 
inwardly against the brake wedges 80. As the brake mandrel moves inwardly, 
the brake wedges 80 are forced radially outward by the brake cap against 
an interior cylindrical surface 88 of the bore of the piston rod, 
balancing the frictional force of the brake against the expansion force of 
the work piece. 
Each brake wedge is formed of a suitable rigid heat resistant material 
which is used in automotive brake linings. The brake wedges have a 
cylindrical outer surface having a circumference slightly smaller than the 
interior surface 88 of its base. 
The force of the brake wedges on the cylindrical surface of the bore is a 
predetermined frictional force equal to or slightly greater than the force 
of expansion created by the metal as it is being heated by the welding 
current. Thus, the frictional force holds the electrode against outward 
displacement during the expansion of the work piece. However, once the 
metal softens and the counterforce of the work piece to the squeezing 
force of the electrodes is reduced, the squeezing force overcomes the 
frictional force and reduces counterforce to permit the piston rod 50 and 
electrode 54 to move inwardly. The pressure equalizing device permits 
electrode 54 to indent the work piece after the metal softens, thus 
producing a weld of superior quality and consistency. 
The brake wedges are released by introducing pressurized air through port 
P.sub.5 to act against the brake piston 84 to move the brake rod 76 and 
brake mandrel 82 in a direction away from the brake wedges shown by Arrow 
A of FIG. 4. The biasing member 22 moves the slide bar to return the 
electrodes to the starting position. 
A first preferred alternative embodiment of a pneumatic cylinder 148 for 
use in a welding apparatus 10 is shown in FIGS. 7 and 8. The cylinder 148 
includes a ball screw assembly 134, a unidirectional clutch 136 and a 
brake assembly 138. The pneumatic cylinder 148 is mounted to the mounting 
bracket 36 of the pressure equalizing device as described above (FIG. 1) 
by bolts (not shown) which engage a flange 130. 
As best shown in FIG. 7 the pneumatic cylinder 148 includes a cylinder 
barrel 156 mounted to an end piece 158 and a cylinder cap 162. The piston 
rod 150 is reciprocally movable through an aperture in the end piece 158. 
The piston rod has a working end portion 140 and inner end portion 142. As 
shown in FIG. 8, the working end portion 140 has a pair of flat surfaces 
132 which mate with corresponding surfaces of the aperture of the end 
piece to hold the rod 150 in alignment as it moves. The working end 140 
has a mount 141 with slots 160 for mounting of the electrode holder 52 for 
supporting the electrode 54 in the same manner as discussed above. The 
inner end portion 142 which may be separately formed and threadably 
attached to the working end portion 140. A roll pin 188 is used to lock 
the inner end portion to the rod 150. The inner end portion 142 includes a 
flange 172 and stepped axial bore 180. The piston rod 150 is supported 
within the barrel 156 in an axial bore 144 in a cylinder head 146. The 
bore 144 has an O-ring 152 in a slot to provide a seal. 
An inner cylinder head 164 and an outer cylinder head 166 are mounted to 
the rod. The inner piston head 164 moves in a first chamber 168 between 
the end piece 158 and cylinder head 146. The outer piston head 166 moves 
in the second chamber 170 formed between the cylinder head 146 and the cap 
162. The outer piston head 166 is held in position on the piston between 
the flange 172 on the inner end portion 142 of the rod and a retaining 
ring 174 mounted in a circumferential slot formed on the rod. 
A forward stroke port P.sub.1 opens into an annular passageway 174 to 
introduce pressurized air to act on the inner piston head 164. A second 
forward stroke port P.sub.2 is provided in the cylinder cap 162 having a 
passage 176 for introducing pressurized air into the second chamber 170 to 
act on the outer piston head 166 to extend the rod. Pressurized air is 
supplied to both P.sub.1 and P.sub.2 at the same time to extend the rod. A 
return port P.sub.3 is positioned in the cylinder head 146 to permit 
pressurized air to be introduced into the second chamber 170 to move the 
outer piston head 166 away from the cylinder head 146 to actuate a return 
stroke. A breather 178 is mounted in the end piece 188 to permit 
introduction and expansion of ambient air into a non-working portion of 
the cylinder. 
The ball screw assembly 134 includes a ball screw nut 194 and a ball screw 
rod 196. The ball screw nut is threadably attached to an outer threaded 
portion 182 of the axial bore 180 of the inner rod. The ball screw rod 196 
has a threaded end portion 198 and a smooth end portion 199. The threaded 
end portion 198 is threadably received within a threaded bore of the ball 
screw nut 194 and an inner threaded portion 184 of the axial bore 180. 
The ball screw rod 196 is supported for rotation within the cylinder cap 
162 by a thrust bearing assembly, including two needle thrust bearing 
packages 102. One thrust bearing 102 is mounted between a collar 104 on 
the ball screw rod 196. The other is mounted between the end cap 162 and a 
bear hug nut 106. The needle thrust bearing assembly is advantageously 
provided to permit the ball screw rod 196 to rotate freely within the cap 
162 and absorb the axial thrust which occurs as the result of the movement 
of the rod 150. An O-ring 108 is disposed in the cylinder cap about the 
ball screw rod 196 to seal the cylinder. 
The unidirectional clutch assembly 136 is mounted to the smooth end portion 
199 of the ball screw rod 196 within a cylinder housing 110 which is 
fixedly mounted to the cylinder cap 162. The unidirectional clutch 
assembly 136 may be of any conventional type, such as Model FSO 300 
manufactured by Warner Brake. The unidirectional clutch assembly 136 
permits rotation of the ball screw rod 196 in one direction only when the 
clutch assembly is held against rotation by the brake assembly 138. The 
brake assembly 138 is of any conventional type, such as produced by Warner 
Brake, and is mounted to engage a brake rod 112 extending from the 
unidirectional clutch assembly. The brake rod 112 is mounted in a needle 
bearing 114. The electric brake assembly 138 has brake shoes (not shown) 
which are biased into engagement with the brake rod 112 to prevent 
rotation of the unidirectional clutch assembly 136. Because the rod 150 is 
held against rotation by the flat surfaces 132, the ball screw rotates in 
a first direction, for instance, clockwise, when the rod 150 is extended 
outwardly and rotates in an opposite direction, for instance, 
counterclockwise, when the rod 150 is returned. 
When the electric brake assembly 138 is energized, the ball screw rod 126 
is free to rotate in either direction to move the rod 150. However, when 
the electric brake assembly 138 is deenergized, the brake rod 112 and 
unidirectional clutch assembly 136 are locked against rotation. The 
unidirectional clutch assembly then is selectively operable to permit the 
ball screw rod 196 and piston rod to move in only one direction. 
Thus, the first preferred alternative embodiment of the cylinder 148 
advantageously locks the rod 150 and electrodes from outward displacement 
during expansion of the weld nugget. The pneumatic cylinder applies a 
squeezing force in the same manner as disclosed above. When the brake 
assembly 138 is energized, the rod 150 and electrodes 42 and 54 are locked 
against outward movement during expansion of the work piece. However, the 
squeezing force which is applied through ports P.sub.1 and P.sub.2 to 
force the electrodes together against the work piece is sufficient to move 
the electrodes together after the metal softens and the counterforce is 
overcome. The inward movement of the electrode is permitted by the ball 
screw assembly and unidirectional clutch assembly. Thus, the first 
preferred embodiment does not require balancing the frictional force with 
the expansion force as disclosed above to permit a precise control of the 
movement of the electrodes during the welding cycle. 
A second preferred embodiment of a pneumatic cylinder 248 with a caliper 
assembly is shown in FIGS. 9, 10, 11, 12, 13 and 14. As shown in FIG. 9, 
the pneumatic cylinder 248 has a cylinder barrel 256 enclosed by an end 
piece 258 and a cap 262. The pneumatic cylinder 248 has a reciprocally 
mounted rod 250. The rod has an intermediate portion 242 extending between 
a working end 240 and a rod extension 244. The working end 240 is formed 
as discussed above for the first preferred embodiment. 
As shown in FIGS. 9 and 11, the rod extension 244 has a pair of spaced 
apart flat surfaces 245 having friction members 247 mounted thereto. The 
end piece 258 and cap 262 have apertures formed to permit reciprocal 
movement of the rod 250. A flange 130 extends from the cylinder cap 262 
for mounting to the mounting bracket 36 (as discussed above). 
A cylinder head 246 is mounted in the cylinder 248 to form a first chamber 
268 and a second chamber 270. An inner piston 264 is mounted to the rod 
250 in the first chamber 268 and an outer piston 266 is mounted in the 
second chamber 270. The cap 262 has a port P.sub.1 communicating by way of 
a passageway 272 with a radial bore 278 in the rod 250. The rod 250 has an 
axial bore 274 extending from the radial bore 278 to a second radial bore 
276 disposed adjacent the inner piston 264. Pressurized air enters port 
P.sub.1 to extend the rod 250. The pressurized air is delivered into the 
passageway 272 to act on the outer piston head 266 and through the radial 
bores 278, 276 and axial bore 274 of the rod to a passageway 280 formed in 
the cylinder head 246 to act on the inner piston 264 and thereby extend 
the rod 250. Port P.sub.3 is formed in the cylinder head 246 to deliver 
air into the second chamber 270 to act on the outer piston 266 to retract 
the piston 250. A breather 178 is mounted in the end cap to permit 
introduction and expulsion of ambient air from a nonworking portion of the 
first chamber. 
A caliper assembly 238 is shown in FIGS. 12, 13, and 14. As shown in FIGS. 
12 and 13, a caliper assembly 238 is mounted to the cylinder cap 262 of 
the cylinder by a pair of threaded bolts 242. The caliper assembly 238 
includes an inner plate 210, an outer plate 212 and an actuator 214. The 
outer plate 212 has a pair of blocks 216. Each block 216 has a bore 218 to 
accept one of the pins 242 and a bushing 220. Disposed on each bolt 242 is 
a spring 246 and bushing 247 between the cylinder cap 262 and blocks 216 
to bias the assembly 238 away from the cylinder cap 262. As shown in FIG. 
14, the outer plate 212 has two spacers 222 mounted on an inner side. The 
spacers 222 include a pair of bores 224 for accepting pins 226 for 
mounting the outer plate to the inner plate 210. The inner plate 210 is 
generally planar, having a center opening 230 and a pair of cylindrical 
mounts 232 with throughbores 234 disposed to accept the pins 226. The 
inner and outer plates are disposed on either side of the rod extension 
244 and friction members 247. A U-shaped support member 236 is welded to 
the inner plate 210 to extend over the center opening 230 between the 
inner and outer plate and around the rod extension 244. A friction plate 
280 is mounted in the center of the support member 286 parallel and spaced 
apart from the friction member 247 of the rod 244. As shown in FIG. 14, 
the actuator 214 is a pneumatic cylinder having an actuator rod 284. The 
actuator 214 is mounted by screws 220 to the inner plate. The actuator rod 
is disposed to be directed into the center opening 230 of the inner plate 
towards one of the friction plates 247. 
As shown in FIG. 14, the friction members 247 are disposed between the 
friction plate 280 and actuator rod 284 of the brake cylinder which are 
advantageously all formed of the same material. Thus, when the actuator 
rod 284 is extended, it contacts the friction plate 247 of the extension 
rod 244 and draws the friction plate of the inner plate against the 
opposite side of the extension rod 244 by pushing against the rod 244 like 
a caliper. In this way, the rod and electrodes are held against outward 
displacement during the expansion of the work piece. However, the brake 
assembly is free to move inwardly on the bolts 242 to indent the weld 
nugget after expansion when the squeezing force of the electrodes 
overcomes the counterforce of the metal work piece and the brake assembly 
then moves inwardly by compressing the springs 246 on the bolts 242. 
The method of operation of the improved welding apparatus according to the 
invention includes first positioning the electrodes 42 and 54 on either 
side of the work piece 14, as best shown in FIG. 1. As shown in FIG. 2 and 
FIG. 4, pressurized air is introduced into ports P.sub.1 and P.sub.2 to 
extend the piston rod 50 and electrode 54 against the work piece. The 
pressure of the electrode 54 on the work piece forces the outer arm to 
slide inwardly, drawing electrode 42 against the biasing member to abut 
the work piece as shown in FIG. 2. The pressure of the electrodes on 
either side of the work piece is equalized by movement of the slide bar 
against the biasing force of the spring. When sufficient pressure, for 
instance, 800 lbs/sq. in., to squeeze the work piece between the 
electrodes. The brake is applied to prevent separation of the electrodes 
during expansion of the work piece. The brake wedges are set by 
introducing pressurized air through P.sub.4, thereby forcing the brake 
wedges apart against the inner surface of the piston rod bore to 
mechanically lock the piston rod in position. The welding current is then 
applied to form a weld nugget. After the nugget has been formed, the 
current is terminated and the brake is released. 
Because an important aspect of the invention is preventing outward 
displacement of the electrodes during the application of weld current, it 
is within the contemplation of the invention to adjust the pressure 
setting the brake at a level which will permit the squeezing force of the 
cylinder to move the electrodes together after expansion of the weld 
nugget. Thus, the electrodes are free to move inwardly firmly contacting 
the weld during contraction of the nugget as it cools. 
After the weld has cooled, the electrodes are moved apart and the work 
piece removed to complete the cycle. 
It has been found that locking the piston rod reduces spark expulsion and 
the increased pressure which results from the expansion of the weld nugget 
during the application of the weld current results in a much improved weld 
over previous methods. 
It should be clear that variations of the invention may be made without 
departing from the scope and spirit of the invention. For instance, it is 
not necessary to have a double piston arrangement as disclosed. Likewise, 
many variations in the manner in which the electrodes are fixed against 
outward expansion during the application of the welding current are within 
the scope of the invention.