WELDING SYSTEM

Abstract: A welding gun and transformer having windings with reduced resistance and reactance, thus drawing less current, and improved means to remove heat. The system transformer has substantially reduced weight and may be operated at high duty cycles and in a welding gun performing a large number of welds per hour. The transformer primary is formed with a coiled hollow tube (42, 43, 44, 45, 112, 114, 116, 118, 120, 122) and coolant is flowed through the coil to directly cool the transformer. The secondary is formed with plate-like members (63, 64, 65, 66, 67, 130, 132, 134, 136, 138, 158) physically adjacent the primary coil so that heat from the secondary is quickly dissipated through the primary.

Description: WELDING SYSTEM TECHNICAL FIELD The present invention relates to an improved electrical resistance welding gun and, more particularly, to an improved transformer for an electrical resistance welding gun. BACKGROUND ART Electrical resistance welding is, of course, well-known and electrical resistance welding guns are frequently used in the fabrication of vehicles to weld together parts of the vehicle such as floor pans, fenders, roofs, hoods, doors, frames, etc. " Electrical resistance welding guns typically comprise first and second elec¬ trodes moveable relative to each other and oppositely disposed relative to one another for welding, with each electrode being attached to a body member (called an arm), and an electrical transformer including primary windings and secondary windings. One type of electrical resistance welding gun provides the transformer at a remote location from the gun itself and the electrical power is coupled to the electrodes by means of an elongated cable. This type of welding gun allows the electrodes to be taken to the workpiece while the transformer is relatively station- ary at a location remote from the workpiece. In such a welding system, the majority of the electrical power necessary for the system is lost transferring power from the transformer to the electrodes. That is, the power required to weld the workpiece is normally quite small as compared to the total power requirement of the welding system. Thus, in a welding system of the type 2 just described, the actual weld (i.e., I R between the electrode tips) consumes less than 2 kilowatts, the remainder of the welding gun (excluding the cable) may consume 15-25 kw and the cable itself is a primary source of energy loss such that a ten foot cable may consume as much as 200 kw. A second type of welding gun utilizes the transformer as a structural part of the arm of the welder. Such a welding gun is disclosed in my United States Patent 4,233,488 issued November 11, 1980. Since the transformer is physically adjacent the -electrode, a long cable is not necessary. This avoids the problem of power loss due to a long cable from the transformer to the electrode. One problem in a resistance welder is that each structural member, i.e., each arm of the welding gun, is inherently both a resistance and a re- actance. Furthermore, in a welding gun having a wide throat, the air gap adds a substantial reactance to the welding circuit. In fact, it is often the case that in a resistance welder, the welding gun itself provides a resistance and a reactance which far exceeds the re- sistance and reactance of the load. In other words, the resistance and reactance of the equipment far ex¬ ceeds the resistance and reactance of the material being welded. The welder of U.S. Patent No. 4,233,488 pro¬ vides a reduced impedance of such welding guns. This invention provides a further improved transformer which may be utilized as a structural part of the body member or arm of an electrical resistance welding gun. A third type of electrical resistance welding gun uses a transformer attached to the arm or body member of the welding gun, rather than as a structural part of the welding gun arm. The transformer is adjacent the electrodes and a long cable is not necessary. Since transformers may burn out, it is beneficial to have a transformer attached to the arm of the welding gun be¬ cause such transformers may be easily replaced. Also, 5 if the power requirements of the system change, a dif¬ ferent capacity transformer may be readily attached to the arm of the welding gun. While a basic objective in an electrical re¬ sistance welding gun is to conserve energy by the re- .0 duction of line current, there are various conflicting sub-problems which occur. Specifically, the minimum line current necessary for welding is related to the load current needed for welding .in proportion to the transformer "turns ratio", which is the ratio of the _5 number of primary turns to the number of secondary turns. To minimize line current, a higher "turns ratio" is needed. However, in order to provide a sufficient secondary voltage to overcome "the total -impedance of the system, a lower "turns ratio" is needed. But, once 0 a lower "turns ratio" is provided, the result is the need for a higher line current. Thus, the desire to reduce line current has been frustrated by the necessity of a sufficiently high line current in conjunction with a sufficiently low 5 "turns ratio" to provide not only the necessary power for welding but also the necessary secondary voltage to overcome the impedance of the welding system. A problem which arises with transformers for welding guns is the extreme amount of heat generated by 0 the gun. The heat may have a pronounced deleterious effect on the transformer and thus systems have been developed to dissipate the heat and to cool the trans¬ former. In the use of prior art electrical resistance welders, it has been customary to provide a cooling 5 member through which a coolant is flowed for the pur¬ pose of cooling the transformer of the welding gun. OMPI The cooling member must be thermally conductive, to draw the heat from the transformer, and a cooling fluid or coolant is flowed through the cooling member. Typically, copper tubes are used as the cooling member because of the high thermal conductivity of the copper. However, the use of a cooling member increases the weight of a welding gun and the use of a metal cooling member increases not only the weight but also the resistance and the reactance of the .welding gun. Portable electrical resistance welding guns which are moved to a workpiece are often attached 'to "robots", i.e., programmable machines which move the welding gun to a desired position, cause the electrodes to close upon the v/orkpiece, and control the application of the welding current through the electrodes to weld the workpiece. If the electrical resistance welding gun is to be utilized with a robot, -the -use of a remote trans¬ former and a long cable from the transformer to the electrodes still results in the energy loss problem described above. Thus, the present day approach to the use of electrical resistance welding guns in conjunction with robots dictates that the transformer will either be a structural part of the arm of the welding gun or attached to the arm of the welding gun. In either event, however, the use of a robot results in an additional problem, namely, the criticality of the weight of the transformer. Because of the combination of the speed at which robot-controlled welding guns are operated, especially in the fabrication of vehicles, it is neces¬ sary to reduce the weight of the welding gun as much as possible. For example 3600 welds per hour is a de¬ sirable speed for a robot-controlled welding gun. At such a rate, which is one weld per second, the cycle of the robot-controlled welding gun would be: one-quarter second to move into welding position and grab the work- piece between the electrodes; one-quarter second to weld; one-quarter second to hold the welded workpiece while the weld cools; and one-quarter second to release the workpiece and move out of welding position. Since 5 one-fourth of each cycle is the actual welding, such a system has a 25% duty cycle. With the prior art welding guns, it was not possible to make a transformer of suf¬ ficiently light weight to be moved by the robot at the aforementioned rate while still providing cooling which _0 would prevent the transformer from burning up at the 25% duty cycle. On the other hand, if the transformer (including the cooling member) was of a sufficient size to provide the necessary cooling at a 25% duty cycle, the transformer would be too heavy to be moved by robots .5 operating at the desired speed of 3600 welds per hour. Thus, industrial robot-controlled welding guns have used the technique of a large, remote transformer and a cable for transferring the welding power to -the elec¬ trodes. This, of course, has resulted in relatively 0 inefficient, high energy loss systems. The present invention overcomes the afore¬ mentioned problems relating to electrical resistance welders in general and in particular to electrical re¬ sistance welders for use in conjunction with a robot, 5 by providing improved electrical resistance welding guns and transformers. DISCLOSURE OF THE INVENTION The present invention overcomes the problems of the prior art by compleτ * ely eliminating the pre- 0 viously used separate cooling member for the primary of an electrical resistance welding gun, while still pro¬ viding a flow path for a coolant to cool the primary. This substantially reduces the weight, resistance and reactance of the welding gun thus reducing the line current and power necessary to operate the electrical resistance welder. Specifically, the present invention is directed to a method, apparatus and system for maintaining the function of cooling by providing a primary transformer winding formed of a hollow tube and flowing the coolant through the primary winding. Thus, the primary winding is directly cooled by the flow of a coolant. Since, in a resistance welder, a .portion of the primary coil is adjacent the transformer secondary, the primary coil also serves as a heat sink to draw heat from the second¬ ary onto the primary. The flow of coolant through the hollow primary coil cools both the primary and the secondary and thus generally eliminates the need for a separate cooling member for the transformer secondary. The present invention further overcomes the prior art problems described above by providing a light¬ weight self-cooling electrical transformer for a welding gun and, more particularly, adaptable for use in a robot- controlled welding gun where -it is attached to the welding gun arm, thereby eliminating the power loss of a long cable, where the transformer has a substantially re¬ duced resistance and reactance, thus reducing the line current and power necessary to operate the electrical resistance welder, and with the transformer being of substantially reduced weight. The transformer thus may be used with high speed robots and provides sufficient cooling to avoid burning up of the transformer at high duty cycles. This invention permits the design and manu¬ facture of transformers having unusually varied appli¬ cation flexibility with minimal tooling and inventory. The novel windings- may be designed to provide,- through the variety of interconnection arrangements available, - a plurality of voltage selections for both the primary and the secondary. Transformers for many varied welding applications may be assembled from a few "standard" primary coils and secondary turns. Specifically, the present invention is further directed to a light-weight, self-cooling transformer for the end of the arm of a robot-controlled electrical resistance welding gun. The transformer is characterized by windings that are closely coupled together both therm¬ ally and electrically. Each secondary turn of the improved trans- former of this invention is preferably a single sheet¬ like element having two opposed generally planar sur¬ faces. The secondary turns provide a large ratio of cross-sectional area to surface area and provide short thermal paths to the surfaces of the turns for heat developed as a result of the resistivity of the con¬ ductor and a large surface area from which the heat may be carried away. The incorporation of such secondary turns into transformers of the invention permits a trans¬ former with a low secondary winding temperature rise, low secondary electrical losses and a high degree of coupling between the secondary and primary windings. The primary winding is preferably a plurality of multi-turn coils formed with opposed generally planar side portions. At least some of the primary coils of the winding are wound with each turn of the conductor stacked on top of a proper turn to form coils with the exposed conductors of each turn lying in two substanti¬ ally planar surface portions at each side of the coil. Such preferable primary and secondary coils are arranged with their generally planar side portions thermally coupled together but electrically isolated from each other. The thermally coupled coils may be provided with means to remove the heat generated by the power loss within them. At least some of the coils of the primary wind may be wound with tubular conductor, and preferably a tubular conductor having a square-shaped perimeter. The primary coils formed with such con¬ ductors may have substantially flat surfaces at both sides of the coil and their ends may be connected with a source of coolant, such as running water, to provide means to carry heat away from the windings. The primary and secondary windings may be insulated from each other and from the core in the manner known in the art. Barrier means may be interposed be- tween each primary and its adjacent secondary. The barrier means provides electrical insulation to prevent a short between the primary and secondary windings and has limited thermal resistance so that coolant flowing through the primary coils will carry away heat from the secondary winding as a result of its conduction through the barrier to the primary coils. The above features permit a light-weight, more compact transformer to be utilized at the high- duty cycles and to be particularly and easily adapted for a variety of uses as a welding transformer in a robot-controlled welding gun. BRIEF DESCRIPTION OF THE DRAWINGS The various objects and advantages of the present invention, together with other objects and ad- vantages which may be attained by its use, will become more apparent upon reading the following detailed descrip¬ tion of the invention taken in conjunction with the drawings. In the drawings, wherein like reference numerals identify corresponding parts: Figure 1 is a side elevation view, partly broken away, of a portable resistance welding gun of the present invention with the transformer as a structural part of the welding gun arm; Figure 2 is an enlarged cross-section view of the upper arm of the resistance welding gun of Figure 1 as seen in the plane of arrows 2-2 of Figure 1; Figure 3 is a front elevation view of a pair of primary windings of the transformer of the electrical resistance welder of the embodiment of Figure 1; Figure 4 is a side elevation view of the pair of primary windings as seen in the plane of arrows 4-4 of Figure 3; Figure 5 is an exploded partial top elevation view of the pair of primary windings as seen on the plane of arrows 5-5 of Figure 3; and Figure 6 is an exploded partial perspective view of one arm of the resistance welder according to the embodiment of Figure 1. Figure 7 is a front elevation view, partly broken away, of a transformer according to the present invention adapted to be attached to the arm of an -elec¬ trical resistance welding gun; Figure 8 is an end elevation view in the plane of arrows 8-8 of Figure 7 illustrating the transformer of the present invention; Figure 9 is an end view, partially exploded, illustrating the primary windings of the embodiment of Figure 7; Figure 10 is a front elevation view illustrating the configuration of both the secondary winding and the barrier means of the embodiment of Figure 7; and Figure 11 is an exploded view illustrating several of the primary windings of the embodiment of Figure 7 and the connections therebetween. BEST MODES FOR CARRYING OUT THE INVENTION With reference to Figure 1, a portable welding gun 10 according to one embodiment of the present invention includes a gun body having an upper arm 12 and a lower arm 14. The upper and lower arms are interconnected by a vertical member 16 and the two arms 12, 14 and the vertical member 16 comprises a U-shaped throat. The vertical member 16 includes two castings 18, 20 which are pivoted together at a pivot 22. Each casting in¬ cludes a rearward extension 24, 26, respectively and a hydraulic piston or fluid actuated cylinder 28 is con¬ nected between the extensions. The cylinder 28 may be operated by any conventional fluid including air. Actu- ation of the cylinder 28 serves to move the upper and lower arms 12, 14 closer to or farther away from each other by pivoting the same about the pivot 22. In this fashion, the welding gun may be fully opened up by draw¬ ing the extensions 24, 26 toward each other and the gun may then be inserted over a workpiece. Thereafter, the arms 12 and 14 are moved toward each other so that weld¬ ing may be accomplished. The upper arm 12 includes a first electrode holder 30, such as an ejector type holder, at the op- posite end Of the arm from the vertical member 16. The electrode holder may be secured in a preselected posi¬ tion, by conventional techniques as set forth in my prior patent, or by bolts 31, and a first or upper weld¬ ing electrode 32 is secured in the upper electrode holder. Similarly, the lower arm 14 includes a second electrode holder 34 positioned by bolts 35 and a second or lower welding electrode 36 is secured in the electrode holder 34. A flexible electrical connecting shunt 38 is secured by bolts 40 at each end of the shunt to the upper and lower castings 18, 20, respectively, so that the upper arm and lower arm may be electrically con¬ nected together. The welding gun 10, including the arms, vertical member, electrode holders and electrodes are, of course, made of a metal which exhibits a high degree of electrical conductivity. According to the principles of this embodi¬ ment of the invention, a first linear transformer is provided which also functions as a structural part of the upper arm 12. A second linear transformer is pro- vided to function as a structural part of the lower arm 14. It should be pointed out at this time that the presently described structure may be made by eliminat¬ ing the pivot 22 and providing a different technique and structure for accomplishing movement of the elec- trodes toward and away from each other such as, for example, as set forth in my prior U.S. Patent No. 4,233,488. With reference particularly to Figures 1-6, one of the linear transformers of the present invention will now be explained. Specifically, the linear trans¬ former which is part of the upper arm 12 is illustrated in Figures 2 through 6 and it should be appreciated that the linear transformer of the lower arm 14 will be the same although its orientation is inverted relative to the orientation of the transformer of the upper arm. It must be appreciated, therefore, that the cross- sectional view of Figure 2 shows the relative position of the parts with respect to the upper arm 12. The linear transformer of the present invention includes a plurality of primary windings or coils 42, 43, 44, 45. Four such coils are illustrated in Figure 2 and it should be appreciated that more or fewer primary coils or wind¬ ings may be used. Each primary coil is formed as a flat, oval pancake comprising a plurality of turns of primary winding- According to the principles of the present invention, the primary winding is formed of hollow copper or aluminum tubing or hollow wire such as .635 cm square or .476 cm square, and the tubing has a .3175 cm square hollow core. The tubular primary con- ductor provides a path for coolant flow and means for removing heat from the conductor. The tubing is elec- trically insulated before being wound into the flat, oval pancake form. Typically, a material such as Kapton by DuPont may be wound around the tubing and thereafter baked onto the tubing as the electric * 5 insulating material. Other electric insulations such as synthetic varnish, e.g., polythermalse, an aramide, may also be used. The use of such synthetic varnishes is known for use in electrical apparatus. The number of turns per coil, number of coils, 0 and size and shape of the tubular conductor may be de¬ signed to accommodate a variety of voltage and current capacities for any given size of magnetic core. The primary coils may be designed to permit their convenient interconnection to provide a variety of " primary voltages 5 suited to popular welding applications. Preferably, the primary coils are designed to be wound or inter¬ connected in pairs and to present the connections to each pair at the outside of the windings. A preferred technique for forming the trans- 0 former primary will now be explained. The transformer primary is preferably formed with a plurality of coils. Each primary coil is separately wound about a mandrel. When the mandrel is removed, each primary coil has a hollow central portion 50. Each primary winding coil, 5 which is part of the primary, is initially a long straight section of hollow metal tubing with first and second ends 46, 48 (see Figures 4 and 5). The first coil 42 is wound as a flat-pancake with end 46 extend¬ ing outwardly of the coil and end 48 at the center. 0 The second coil 43 is wound as a flat pancake with end 46a at the center and end 48a extending outwardly. The two center portions of coils 42 and 43, i.e., ends 48 and 46a are joined by a hollow metal connector 49 which may be swaged onto the ends of the coils. Pre- 5 ferably, the connector is made of copper. Prior to forming the coil as a pancake, the tubular wire is OMP wrapped about a mandrel into the flat oval pancake type configuration. Thereafter, the mandrel is removed which results in a flat pancake coil which is a primary winding having a hollow oval core 50. As a first step in con- necting the coils, the coils are actually arranged in "pairs" with coils 42 and 43 comprising the first pair and coils 44 and 45 comprising the second pair of coils. The two coils within each "pair" of coils are joined by the connector 49 as heretofore described. As an alternative technique for forming the preferred "pairs of coils", a "pair" of coils may be wound from a double length hollow copper tubing by start¬ ing at the center of the tubing and winding one half the length of the tube clockwise about a mandrel and the other half of the length of the tube counter¬ clockwise about a mandrel thus providing " a continuous double coil eliminating the need for connector 49. Regardless of which of the aforementioned techniques is employed to form "pairs" of coils, each "pair" may be electrically connected to the next "pair" in order to provide a single continuous electrical path through the primary of the transformer. Specifically, as illustrated in Figure 6, and as will be explained in greater detail hereinafter, an adapter in the form of a short, hollow metal tube 71 may be connected between the second end of the second primary coil and the first end 48 of the third primary coil to interconnect the first pair of coils to the second pair of coils. To provide additional structural support for the primary windings, a series of thin, flat rectangular metallic plates 52, 54, 56, 58, 60 are provided with one primary winding between each pair of adjacent plates- These support plates are longer than the coiled length of a primary winding and of a height less than half the height of the primary winding. Each of these plates is positioned on opposite sides of the upper part of the primary winding leaving the bottom part of the primary winding and the hollow core 50 of the primary coil ex¬ posed. To avoid a short circuit condition during opera¬ tion of the welder, each of the support plates is severed or cut as at 61 and then filled with a rigid electrically insulating material such as a rigid urethane, as at 62, to retain structural rigidity and integrity of the support plates. After the support plates and primary coils are properly positioned relative to each other the composite assembly may be taped with insulating material. The secondary for the linear transformer of the present invention icludes a plurality of flat metal plates ' 63, 64, 65, 66, 67 each of which plates is secured on opposite sides of a primary winding below the hollow core 50. If there are four primary- coils there are preferably five secondary windings or plates. Since each primary coil is between two secondary plates, the number of plates should be one more than the number of primary windings. An electrically insulating and therm¬ ally conductive material 69 is placed between each side of the pancake coil and the support and secondary plates, as is often done in all transformers, and a typical material is polyester cloth sheets having a thickness o ~ f .05 cm. Lastly, each transformer includes an iron core comprising two core halves 69, 70. Each of these iron core halves is formed as an elongated U-shaped member and when the halves are assembled together they form an elongated hollow, rectangular member. One pair of the legs of each of the core members are inserted through the hollow portion 50 of each primary coil and the secondary of each transformer is positioned interi¬ orly of the iron core halves. To summarize the construction of the linear transformers, each primary is constructed by coiling tubular hollow copper wire, coated with varnish or other electrical insulating material about a mandrel to obtain the desired number of turns. The mandrel is removed and this results in a pancake type coil with an opening 50 in the center. After the support plates for the primary, and the secondary transformer plates and insulating sheets are placed in position, as will be more fully described, an iron core is slidably inserted in the opening 50 provided in the primary coils. Each half of the iron core extends down one side of the secondary and across half of the bottom of the secondary and is inserted half way through the openings 50 in the pri- mary pancake type coils. The entire linear transformer may be encapsulated in a suitable insulating material as described in my prior patent or may alternatively be wrapped with an electrically insulating tape. As may be appreciated, the electrical current drawn by the welding gun 10 causes the temperature of the entire gun to rise. The heat build up in the gun militates against continued efficient operation of the welding gun. For this reason, welding guns of this type have heretofore been provided with cooling means such as a recirculating fluid coolant which flows through suitable passages within an auxiliary cooling member as described in my prior U.S. Patent No. 4,233,488. The fluid is generally water. According to the principles of the present invention, in the preferred embodiments I have eliminat- ed completely the need for an auxiliary cooling member and I flow the coolant directly through the hollow tube wire of each pancake type primary winding. The coolant flowing through each primary coil directly cools each primary. In addition, since part of each primary is adjacent to two secondary members, as previously de¬ scribed, each primary also functions as a heat sink to OM draw heat from the secondary and thus the coolant flow¬ ing through the primary wire also cools the secondary. Since the sheets 68 are thermally conductive, the sheets do not impede the ability of the primary to function as a heat sink for the secondary. Thus, it may be appreciated that a simple manifold, less complicated than the type previously used with auxiliary cooling members as described in my prior patent, may be utilized in conjunction with the primary coils of the present invention to control the flow of coolant through the primary coils. Of course, the manifold described in my prior patent may be used in the present invention if desired. Since the current must flow the same way through all the coils of each primary as mentioned above, I provide an adapter 71 illustrated in Figure 6. Adapter 71 is a short hollow copper tube, typically of the same material as the coils, and is connected between the second end of the second primary coil and the first end 48 of the third primary coil. That is, since the primary coils are wound in pairs, an adapter is provided to interconnect the first pair of coils to the second pair of coils. Thus, both the current and the coolant flow in the same direction in all primary coils. The particular technique for manifolding and controlling the flow is, of course, the same as it would be if auxiliary cooling members- were provided and hence the manifolding techniques are not described in any greater detail. For the purpose of illustration, however, coolant lines 72 and 73 are il- lustrared m Figure 6 for connecting the circulating coolant to the coils. As may be appreciated, the linear transformer in the upper arm 12 and the linear transformer in the lower arm 14 may be connected electrically through shunt 38 (Figure 1) in series or parallel as required by the rurns ratio of the transformers. The input power to the welding gun is provided through a sheathed cable 74 as described in my prior patent. A first complete electrical path, referred to as the power cir¬ cuit, is provided which path includes the cable and all the primary windings. A second complete electrical circuit, often referred to as the welding circuit, includes the secondary "windings" or plates 63, 64, 65, 66 and 67, the metal electrode holders 30, 34 and the upper and lower electrodes 32, 36. The electrical connec- tions to the primaries and from the secondaries to the electrodes, are not illustrated as they are conventional. A pair of inlet and outlet tubes 75, 76 re¬ spectively, are provided for each electrode holder. The use of a water coolant for the coils and electrode holder will maintain the welding gun at a suitable temperature usually below 48.8°C. Reference should now be had to Figures 1 and 6 for a more detailed explanation of the structure of the resistance welder. It should be understood, however, that the following is only one method of fabri- eating the welder (or parts thereof) and that many other techniques may be employed without departing from the scope and spirit of the present invention. Each electrode holder 30, 34 is formed as a casting arid the upper electrode holder 30 is partially illustrated in Figure 6. The upper electrode holder includes a central bore 78 through which the electrode may be in¬ serted and includes, at one side and more particularly the side of the holder facing the transformer, a series of elongated vertical slots 80. The number of slots is dependent upon the number of support plates and electrical secondaries utilized in a particular linear transformer. The electrode holder 30 may be split metal casting with the parts secured by bolts 31. One end of each support plate for the primary, and one end of each secondary plate, is brazed within each of the slots 80. Thus, one end of each of the support plates and secondary plates is secured to the electrode holder. Means are provided for securing the opposite end of each support plate and secondary plate to the vertical member 16. Specifically, it will be recalled that the vertical member 16 is formed of upper and lower castings 18, 20. Each of these castings has suitable slots 82 facing the slots 80 in the electrode holder. Figure 6 illustrates only the upper casting 18 or upper portion of the vertical member 16. The support plates for the primary coil as well as the secondary plates are similarly brazed or secured in the slots 82 in the casting 18. When a rigid plastic vertical member is used, a mechanical fastening by bolts through apertures in the vertical member and the plates may be provided. The present invention provides excellent cool- ing for low and medium duty cycle welders. When the welder is operated at a high duty cycle if there are a large number of primary coils then there will still be sufficient cooling of the primary and secondary. If, however, the welder is operated at a high duty cycle with only a few primary coils, it may be desirable to add an auxiliary cooling system for the secondary plates. One such system which could be employed would be to use that part of the cooling system described in my prior patent and illustrated interiorly of the iron core. The unique structure of the present invention provides yet another benefit, namely, that higher line current frequencies may be used. The impedance vector diagram of the present invention demonstrates that the reactance of the welder (due to the structure) is small in proportion to the resistance at 60 hertz. A large increase in the frequency (e.g., a seven-fold increase to 420 hertz) will, of course, increase the reactance but the total impedance is not increased seven-fold. Instead the impedance may only be doubled. Since higher line frequencies may be used to provide " 5 increased welding capabilities this provides yet another advantage for the present system since the volume or amount of iron necessary for the welder is drastically reduced com- pared to prior welding systems- 0 Figures 7-11 illustrate another embodiment of the present invention in which the transformer, rather than being a structural part of the arm of the welding gun, as in Figures 1-6, is adapted to be attached or secured to an arm of the gun. 5 The transformer 110 of Figures 7-11 is a self- cooled transformer adapted to be secured to an arm of an electrical resistance welding gun. The transformer includes a plurality of primary windings and six such primary windings 112, 114, 116, 118, 120 and 122 are 0 illustrated in the drawings. As in the previous embodi- ment, each primary winding comprises a plurality of turns of an electrical conductor with the plurality of turns formed as a flat oval pancake, and, as before, each primary winding may be formed of a 5 hollow copper or aluminum tubing or hollow wire such as 0.635 cm square or 0.476 cm square and the tubing has a 0.3175 cm square hollow core, which provides a path for coolant flow and means for removing heat from the conductor. The tubing is electrically insulated before being wound into the fiat, oval pancake form. As illustrated, the primary is preferably formed with a plurality of coils, each of which is sepa¬ rately wound about a mandrel. When the mandrel is re¬ moved, each primary coil will have a hollow central portion 124. Each primary winding coil, which is part of the primary, is initially a long straight section of hollow copper tubing with first and second ends 125, 126 respectively. Each coil is wound as a flat pancake with its "first" end at the outer periphery of the coil, i.e., extending outwardly of .the coil, and with the "second" end at the center or interior periphery of the coil. Then the coils are connected together so that the electrical current flows in a continuous path, e.g., counter-clockwise in Figure 7. Such connection is accomplished by first joining together the "second" ends of the first and second coils 112, 114 and by joining together the "second" ends of the third and fourth coils 116, 118, and by joining together the "second" ends of the fifth and sixth coils 120, 122. For convenience of manufacture the coils may be' assembled as hereinafter described prior to actually connecting the coils to each other. Joining the center or "second" ends of the aforementioned coils is preferably accomplished through the use of a short, straight, hollow metal connector 127 which may be swaged onto the ends of the coils. Pre¬ ferably the connector 127 is made of copper. Thus as a first step in connecting the coils, the six coils are actually arranged in three "pairs" with coils 112 and 114 comprising the first pair, coils 116 and 118 com- prising the second pair of coils, and coils 120 and 122 comprising the third pair of coils. The two coils within each "pair" of coils are joined by the connector 127 as heretofore described. To form "pairs" of coils, each "pair" may be electrically connected to the next "pair" in order to provide a single continuous electrical path through the primary of the transformer. Specifically, a short, straight metal tube section or connector 128 may be swaged or welded onto the "first" ends of ad¬ jacent pairs of coils. Thus, a first connector 128 may be provided to connect the first pair of coils to the second pair of coils, e.g., connecting coil 114 to -^ E OMPI coil 116, and a second connector may be provided be¬ tween coil 118 and coil 120 to connect the second pair of coils to the third pair of coils. Where the primary coils are to be connected in parallel, the appropriate ends of the coils are pro¬ vided with common tubular interconnections to provide a connection for the primary voltage source and for the source of coolant. The primary winding as illustrated comprises a plurality of coils electrically connected in series to form a continuous electrical flow path where current flows in the same direction, e.g., counter-clockwise as viewed in Figure 7. Since each primary coil is formed preferably from hollow tubing and since each of the connectors is a hollow metal member, a continuous in¬ terior flow path can be provided from the first end 125 of the first coil 112 to the first end 125 of the last coil 122. Thus such primary coils are both electric¬ ally and mechanically connected in a single, continuous path. This continuous path is such that both the electricity and a coolant flowing interiorly of the primaries, as will be described, each always flow in the same direction, e.g., counter-clockwise as il¬ lustrated in Figure 7. The transformer 110 of Figure 7 also includes a "secondary" comprising a plurality of thin copper plates 130, 132, 134, 136, and 138. A secondary turn or plate is preferably interposed between adjacent pri¬ mary windings or coils and thus in this embodiment having six primary coils there will be five main secondary plates. One aspect of this embodiment of the present invention is that each secondary turn is preferably at least the same size as each primary winding. Thus, for example, if each primary coil is 12.7 cm high and 19.0 cm wide, then each secondary turn would be about 12.7 cm high and at least 19.0 cm wide. coil 116, and a second connector may be provided be¬ tween coil 118 and coil 120 to connect the second pair of coils to the third pair of coils. Where the primary coils are to be connected in parallel, the appropriate ends of the coils are pro¬ vided with common tubular interconnections to provide a connection for the primary voltage source and for the source of coolant. The primary winding as illustrated comprises a plurality of coils electrically connected in series to form a continuous electrical flow path where current flows in the same direction, e.g., counter-clockwise as viewed in Figure 7. Since each primary coil is formed preferably from hollow tubing and since each of the connectors is a hollow metal member, a continuous in¬ terior flow path can be provided from the first end 125 of the first coil.112 to the first end 125 of the last coil 122. Thus such primary coils are both electric¬ ally and mechanically connected in a single, continuous path. This continuous path is such that both the. electricity and a coolant flowing interiorly of the .. primaries, as will be described, each always flow in the same direction, e.g., counter-clockwise as il¬ lustrated in Figure 7. The transformer 110 of Figure 7 also includes a "secondary" comprising a plurality of thin copper plates 130, 132, 134, 136, and 138. A secondary turn or plate is preferably interposed between adjacent pri¬ mary windings or coils and thus in this embodiment having six primary coils there will be five main secondary plates. One aspect of this embodiment of the present invention is that each secondary turn is preferably at least the same size as each primary winding. Thus, for example, if each primary coil is 12.7 cm high and 19.0 cm wide, then each secondary turn would be about 12.7 cm high and at least 19.0 cm wide. 21 coil 116, and a second connector may be provided be¬ tween coil 118 and coil 120 to connect the second pair of coils to the third pair of coils. Where the primary coils are to be connected in parallel, the appropriate ends of the coils are pro¬ vided with common tubular interconnections to provide a connection for the primary voltage source and for the source of coolant. The primary winding as illustrated comprises a plurality of coils electrically connected in series to form a continuous electrical flow path where current flows in the same direction, e.g., counter-clockwise as viewed in Figure 7. Since each primary coil is formed preferably from hollow tubing and since each of the connectors is a hollow metal member, a continuous in¬ terior flow path can be provided from the first end 125 of the first coil.112 to the first end 125 of the last coil 122. Thus such primary coils are both electric¬ ally and mechanically connected in a single, continuous path. This continuous path is such that both the electricity and a coolant flowing interiorly of the primaries, as will be described, each always flow in the same direction, e.g., counter-clockwise as il¬ lustrated in Figure 7. The transformer 110 of Figure 7 also includes a "secondary" comprising a plurality of thin copper plates 130, 132, 134, 136, and 138. A secondary turn or plate is preferably interposed between adjacent pri¬ mary windings or coils and thus in this embodiment having six primary coils there will be five main secondary plates. One aspect of this embodiment of the present invention is that each secondary turn is preferably at least the same size as each primary winding. Thus, for example, if each primary coil is 12.7 cm high and 19.0 cm wide, then each secondary turn would be about 12.7 cm high and at least 19.0 cm wide. longer than the primary coils. For example, when the primary coil is 12.7 centimeters high and 19 centimeters long, the secondary turn could be made 12.7 centimeters high and 20 centimeters long to provide a projecting portion of the secondary turn for the connection. Where a number of the secondary turns are to be connected in parallel, it may .be easier to alternate the placement of such longer secondary turns on the core so that they may be more easily inter- connected in parallel at each side of the primary coil. The orientation and interconnection of the secondary turns to provide desired secondary voltage and current may be varied with the transformer design of varied applications. As in the previous embodiment, means are pro¬ vided to electrically insulate each primary coil from its adjacent secondary turn. The electrical insulation may again be electrical varnish and/or other- insulating materials commonly used in transformer construction. Because of the controlled temperature rise with trans¬ formers of_ this invention, there is generally no need for special high temperature insulation. However higher temperature insulation will serve to extend the life of a transformer if any problems such as leakage develop with the coolant. Preferably a plurality of barrier means 144 may be provided and one barrier means is interposed between each secondary winding and each primary winding. Each barrier means 144 is of the same size and shape as the secondary turn. The barrier means may be a material such as a glass cloth based polyester laminate sold by the Conolite division of LOF., having a thickness of 0.05 cm. Depending upon the specific transformer, the DuPont Kapton insulation may be a sufficient barrier, e.g., up to about 5kv. The transformer includes magnetic core means such as upper and lower wound steel cores 146, 148, 24 " respectively, with each core comprising generally C- shaped opposed core halves. The core halves of the upper core 146, specifically core halves 150 and 152, are positioned so that the lower legs of each core half extend through the apertures 140 in each secondary, through the corresponding aperture in each barrier means, and through the center 124 of each of the primary coils. Similarly, the core halves 154, 156 of the lower core 148 are arranged so that one leg of each core half extends through the secondary apertures 140, the apertures in the barrier means, and the primary coil apertures 124. It may be appreciated that there are barrier means 144 on each side of each primary coil. An addi- tional secondary turn 158 may be provided exteriorly of each primary windings 112 and 122 although these secondaries 158 are optional. These additional secon¬ dary windings are rectangular shaped plates correspond¬ ing in both size and shape to the secondary windings 130, 132, 134, 136 and 138 but approximately only 1/2 the thickness. Thus, while the secondary windings 130, 132, 134, 136, 138 may be of 0.3175 cm thick copper plate, each additional secondary 158 would be 0.15875 cm thick copper plate. Preferably the primary and secondary winding, the barrier means and the core halves are all placed in proper alignment prior to securing the connectors which interconnect the primary windings to each other. Means are provided for supporting and main- taining the transformer as a compact sub-assembly so that the transformer may be easily and quickly secured to the arm of a welding gun. By way of illustration, the transformer windings, cores and barrier means may be wrapped with electrically insulating material and thereafter encircled by a pair of spaced apart steel bands 160, 162. Clamping means are provided for secur- - SZ ing the steel bands to the transformer, and the clamp¬ ing means includes a pair of elongated metal plates 164, 166 positioned on opposite sides of the transformer. A pair of bolts are provided and each bolt extends through an aperture in the end of plate 164, through the central opening 140 in each secondary winding, through the cor¬ responding opening in each barrier means 144, " through the central aperture 124 of each coil and then through an aperture in the second plate 66. A nut may be placed on the end of each bolt to secure the plates together. In this fashion the transformer may be maintained as a compact assembly. The entire transformer as heretofore described may be housed inside an insulating case 168 which may be made of plastic-. In an electrical resistance welding gun the "secondary circuit" or "welding circuit" components are the electrodes and the secondary of the transformer. To facilitate connecting the transformer secondary to the welding gun electrode, a conventional secondary pad 170 may be provided from the secondary winding ex¬ tending exteriorly of the insulating case. In addi¬ tion, the free ends of the first primary coil 112 and of the last primary coil 122 both extend outwardly of the insulating case to permit both electrical and coolant connections. Although various coolants and cooling systems may be used, I prefer to use water as the coolant as in the previous embodiment and a closed cooling system. The present invention has yielded certain surprising and unexpected results when the transformer is operated and when a coolant is flowed through the hollow interior of the six primary coils. Specifically, with the transformer operating and providing 15 kiloamps welding current at a 25% duty cycle with 3600 welds per hour, water was flowed through the primary coils at the rate of 1.1 liter per minute. The temperature of the water entering the primary was about 15.5°C. The tempera- OMPI 26 ture of the water flowing out of the primary coils was about 57°C. The temperature of the secondary at the water inlet was about 35.5°C which was about 20°C higher than the inlet water temperature. The temperature of the secondary at the water outlet was about 78°C which is also about 20°C higher than the temperature of the outlet water. Thus notwithstanding the presence of thermal and electrical insulation (barrier means) the transformer is maintained suffi- ciently cool to prevent burning up or overheating the transformer. The system as described may be modified for welding aluminum at double the current, i.e., 30 kiloamps. The modification includes first, more iron in the transformer, for the higher voltage required for welding aluminum and second, introducing water at the center of the primary and allowing the water to flow in two paths (one clockwise and one counter-clockwise) toward the two free ends of the primary. The foregoing is a complete description of preferred embodiments of the present invention. Various changes and modifications may be made without departing from the spirit and scope of the present invention. The invention should be limited only by the following claims.

Claims: 27 CLAIMS : 1. A welding system, including an electrical transformer for use with a welding gun including a pri¬ mary connected with a source of energy, a secondary connected with the electrodes of the welding gun, and a core of magnetic material, characterized in that said primary includes a primary coil (42, 43, 44, 45, 112, 114, 116, 118, 120, 122) comprising a hollow, tubular conductive member providing an interior which is coupled to a source of coolant. 2. A welding system, including an electrical transformer for use with a welding gun, including a primary coil connected with a source of energy and a secondary connected with the electrodes of the welding gun, and a core of magnetic material, characterized in that the primary coil (42, 43, 44, 45, 112, 114, 116, 118, 120, 122) and the secondary (30, 34, 38, 63, 64, 65, 66, 67, 130, 132, 134, 136, 138, 158) are closely coupled both electrically and thermally and provided with means to remove heat from the primary coil and secondary. 3. A system as recited in claim 1 or claim 2 characterized in that said primary coil (42, 43, 44, 45, 112, 114, 116, 118, 120, 122) comprises a hollow, tubular conductive member having at least two opposed planar side portions, and is wound from said tubular conductive members with opposed generally or planar sides, and in that said secondary (30, 34, 38, 63, 64, 65, 66, 67, 130, 132, 134, 136, 138, 158) comprises a plate-like secondary member having generally opposed planar sides, at least a portion of which are thermally coupled with at least a portion of a planar side of said primary coil. OMPI 28 4. A system as recited in claim 3 characterized in that said hollow, tubular conductor member has a square perimeter. 5. A system as recited in claim 3 characterized in that said primar (42, 43, 44, 45, 112, 114, 116, 118, 120, 122) comprises a plurality of primary coils and a plurality of secondary members, at least some of said plate-like secondary members being located between primary coils with at least a portion of each of their opposed planar surfaces being thermally coupled with at least a portion of the planar sides of said primary coils. 6. A system as recited in claim 2 including a welding gun, comprising an upper elongated body member (12), a lower elongated body member (14), said upper and lower body members being pivotally interconnected to form a U-shaped structure and having portions lo¬ cated at the opening of the U-shaped, structure that are adapted to carry a welding electrode (32, 36), ch.aracteriz.ed in that said transformer includes at least one linear welding transformer forming a structural part of one of the elongated body members, a primary winding (42, 43, 44, 45) having a plurality of primary coils (42, 43, 44, 45), each primary coil being wound from a tubular conductor to provide at least a portion with a pancake con iguration, and a secondary (30, 34, 38, 63, 64, 65, 66, 67) having a plurality of plates (63, 64, 65, 66, 67) connected to provide current to the portions of body members. (30, 34) adapted to carry the welding electrodes, each secondary plate having two opposed planar surfaces to provide a large surface for transfer of the heat generated by the power loss of the plate, said primary and secondary windings being elec¬ trically insulated from each other and from the core, 29 and means (75, 76) to provide a flow of coolant through the primary coils to remove heat from the transformer windings and welding gun. 7. A system as recited in claim 6 characterized in that each of the primary coils (42, 43, 44, 45) is wound turn upon turn with the tubular conductor having a square perimeter, and the majority (64, 65, 66) of secondary plates are located between two adjacent primary coils so that each generally planar side of a majority of secondary plates is thermally coupled with the- sub¬ stantially flat surfaces of the adjacent primary coil at each of ' its sides to permit increased heat transfer from the secondary winding to the coolant. 8. A system as recited in claim 6 characterized by further including a plurality of support members (52, 54, 56, 58, 60) adjacent part of said primary • - coils (42, 43, 44, 45), said support members and said primary coils comprising said elongated body members. 9. A system as recited in claim 1 characterized in that a plurality of primary coils (42, 43, 44, 45, 112, 114, 116, 118, 120, 122) are formed from a tubular conductor having a square-shaped perimeter so that each such primary coil is formed with substantially flat surfaces at both sides of the coil, and the ends of the primary coils of tubular conductor are connectable with a source of coolant to provide means to carry heat away from the windings. 10. A system as recited in claim 9 characterized in that the secondary (30, 34, 38, 63, 64, 65, 66, 67, 130, 132, 134, 136, 138, 153) includes a plurality of plates (63, 64, 65, 66, 67, 130, 132, 134, 136, 138, 158) and a majority (64, 65, 66, 130, 132, 134, 136, OMPI 30 138) of the secondary plates are located between two adjacent primary coils so that each generally planar side of a majority of secondary plates is thermally coupled with the substantially flat surfaces of the -5 adjacent primary coil at each of its sides to permit heat to be carried away by the coolant. 11. A system as recited in claim 10 characterized in that said plurality of secondary plates comprise generally C-shaped sheets (130, 132, 134, 136, 138, 0 158) having two closely spaced, opposed planar surfaces to provide a large surface for transfer of the heat generated ' by the power loss of the turn. 12. A method of winding a pair of coils for a welding transformer, comprising 5 providing a length of tubular electrical con¬ ductor to be wound into coils, fixing the central portion of the tubular conductor to a winding mandrel, turning the winding mandrel in one direction 0 while placing and supporting each turn of the tubular conductor on top of the prior turn to build a flat pan¬ cake coil with turns in one direction about its center of rotation, turning the winding mandrel in the other direc- 5 tion while placing and supporting each turn of the tubular conductor on top of the prior turn to build a flat pancake coil with turns in the other direction about its center of rotation, and removing the pair of interconnected coils from the mandrel. 13. A welding transformer of the type adapted to be attached to the arm of a welding gun or the like 31 including a primary winding, a secondary, and a magnetic core, characterized in that said primary winding (112, 114, 116, 118, 120, 122) comprises a plurality of spaced apart coils, said primary winding coils having a hollow interior defining a passage for a coolant therein, and being electrically connected in series and mechanically con¬ nected to define a continuous flow path for a coolant; said secondary comprising a plurality of spaced thin flat conductive members (130, 132, 134, 136, 138, 158); one of said primary coils being interposed between two adjacent spaced secondary members so that the primary coils and secondary are arranged in al- ternating sequence; insulation (144) between each primary coil and each secondary for electrically isolating each pri¬ mary coil from the adjacent secondary member,• each primary coil and each secondary member being of substantially the same height and depth so that upon flowing a coolant through said primary winding, heat generated in said secondary members is conducted to said primary winding and dissipated by the flow of coolant through said continuous flow path to cool both said primary windings and said secondary members by the 'flow of coolant through said primary. 14. The transformer of claim 13 characterized in that the secondary members (130, 132, 134, 136, 138, 158) comprise generally C-shaped sheets having two closely spaced, opposed planar surfaces to provide a large surface for transfer of the heat generated by the power loss of the turn and a relatively large cross sectional area with low electrical resistance. 32 15. The welding transformer of claim 14 charac¬ terized in that at least a portion of the primary coils (112, 114, 116, 118, 120, 122) coils are formed by a plurality of turns of a tubular electrical conductor with each turn being wound upon a preceding turn to form a coil having at least one side with its outer edges lying generally in a plane, and wherein each single C-shaped secondary turn (130, 132, 134, 136, 138, 158) is located adjacent at least one of the primary coils of said portion with at least one of its opposed planar surfaces in heat transfer relationship with at least the primary turns forming the one planar side of the at least one primary coil of said portion. 16. The welding transformer of claim 15 wherein each of the primary coils (112, 114, 116, 118, 120, ■ 122) of the primary winding are wound from tubular con¬ ductor having a square-shaped perimeter, and wherein each turn is wound directly on the preceding turn to form primary coils with generally planar sides, and wherein a portion (130, 132, 134, 136, 138) of the secondary turns are located between primary coils (112, 114, 116, 118, 120, 122) with each of their opposed planar surfaces in heat transfer relationship with the • primary turns of the primary coils adjacent each side.

Inventors: SCHWARTZ CHARLES A, SCHWARTZ, CHARLES, A.
Applicants: SCHWARTZ CHARLES A, SCHWARTZ, CHARLES, A.
Application year: 1983
Main classification: H01F27
IPC codes: H01F27