Abstract:
Various methods, systems and products are disclosed for providing an improved welding system which substantially improves the continuous operation of an automated welding system by increasing the amount of time between maintenance shutdowns. One of the disclosed method steps or system elements provides for dipping a front end of a welding torch into a bath of fluid each time the automated welding system moves through a welding cycle or as necessary. A product is also disclosed to best accomplish that step or element. Another method step or system element may include the removal of spatter accumulation via an electromagnetic field that magnetically pulls the spatter without direct contact with the front end of the torch. A further disclosed method step or system element may include lubrication of the continuous electrode used for welding, and may also include a step or element prior to lubrication that involves cleaning the continuous electrode prior to adding lubricant. The steps or elements may vary as to whether or not they are included, or in what sequence. In each combination of method steps or system elements disclosed, however, a significant increase in time of continuous operation between maintenance shutdowns has occurred. A product is also disclosed that will hold various products as needed for the implementation of each disclosed system or method.

Description:
[0001]    This application is a continuation-in-part application of U.S. patent application Ser. No. 10/012,591, filed Nov. 10, 2001, which is a continuation application of U.S. patent application Ser. No. 09/499,199 filed on Feb. 7, 2000, for “Implementation System for Continuous Welding, Method, and Products for Implementation of the System and/or Method”, now U.S. Pat. No. 6,369,357. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The subject invention relates to systems and/or methods of use for significantly increasing the amount of time between maintenance shutdowns in an automatic continuous welding application for an automated welding machine. Also disclosed are products which can be used to accomplish some of the steps of the processes or systems disclosed.  
         BACKGROUND  
         [0003]    In the industry, various welding systems and processes are employed to weld two pieces of metallic material. For example, a diffusion nozzle (or nozzles in the case of twin electrodes) of a continuous electrode is moved near an article or articles to be welded, and an arc is established between the continuous electrode and the article or articles to be welded, so as to raise the temperature of the article or articles to be welded to the point at which the parts locally melt. Throughout the welding process an inert gas is dispensed through a gas diffuser disposed adjacent the nozzle to keep the molten metal at the weld engulfed in a controlled atmosphere. The controlled atmosphere controls the characteristics of the weld deposit as well as excluding air. Alternatively, a gasless wire tube may be used. The gasless wire tube contains chemicals which produce gas. The gases that cause the most difficulty in welding are atmospheric gases, particularly, hydrogen or H 2 O. When any welding process is used, the molten puddle creating the weld should be shrouded or shielded from the air in order to obtain a high quality weld deposit. This can also help arc ignition and the transfer of electrode to pieces welded for a smoother weld.  
           [0004]    A problem typically arises with this type of welding whereby spatter builds up on the front end of the torch, e.g., including a welding nozzle, tip and gas diffuser. Spatter is developed as molten metal droplets from the electrode and molten metal being welded are expelled and strike against the nozzle, tip and gas diffuser. The droplets of molten metal solidify and adhere to surfaces of the front end of the torch as deposits of spatter. When a significant amount of spatter accumulates on the surface of the nozzle, tip or gas diffuser adjacent the nozzle, the flow of inert gas to the weld is disturbed and becomes uneven.  
           [0005]    Conventionally, spatter is removed by using a brush as disclosed in Japanese Patent Application Laying Open Publication Ser. No. 59-73186 (1984), or by using a device with rotary blades to scrape the spatter from the nozzle as disclosed in Japanese Utility Model Application Laying Open Publication Ser. No. 58-47381 (1983). However, the usefulness of these methods is limited as direct contact with the welding nozzle is likely to cause damage to the welding nozzle, and the brushing or scraping of the welding nozzle is extremely time and labor intensive. Another approach involves the use of ceramic welding nozzles, instead of metal welding nozzles, as disclosed in Japanese Utility Model Application Laying Open Publication Ser. No. 48-12323 (1973). However, even though the use of ceramic material reduces the amount of spatter accumulation, spatter removal must still be performed, and a ceramic welding nozzle is even more susceptible to damage when the spatter is removed by scraping or brushing. In all of these cases it is necessary for the operator to be in close proximity to the welding nozzle in order to remove the spatter, which may lead to injuries, such as when an operator is burned by the extremely hot welding nozzle while trying to clean it by hand.  
           [0006]    In order to make the process more streamlined, and to reduce the danger to the operator, spatter may be removed from the welding nozzle by inserting the welding nozzle within an electromagnetic field that magnetically pulls the spatter accumulation from the welding nozzle. A product performing this function is disclosed in U.S. Pat. No. 4,838,287. This product allows the spatter accumulation to be removed with no physical contact to the welding nozzle and with no requirement for the operator to get close enough to the welding nozzle to be burned. This product also can be utilized with an automated welding system application such that the electromagnetic cleaner is placed within reach of an automated welding system, where periodically the automated welding system would automatically move the welding nozzle over to the cleaning station to have the spatter accumulation removed. The product allows the automated welding system to clean the nozzle and continue operation without being shut down. Since the welding nozzle is cleaned often, the life of the welding nozzle is also increased so that it need not be replaced as often as it would without the cleaning procedure.  
           [0007]    However, this product does not work well with a metal welding nozzle because the spatter bonds very strongly to the metal welding nozzle. Typically this product will only be used effectively with a welding nozzle made from either a ceramic or a carbon composite material. Characteristics of carbon composite or ceramic materials make welding nozzles made therefrom resistant to adhesion and to pitting. The resistance to adhesion allows the use of the electromagnetic cleaner to efficiently remove spatter from the various elements of the ceramic or carbon composite welding nozzles.  
           [0008]    In process, the ceramic or carbon composite welding nozzle may be dipped in water prior to cleaning in order to solidify the spatter. The electromagnetic field will not be effective if the spatter is in a liquid or molten state, so the water dip is necessary to insure that the spatter is completely hardened. After dipping the welding nozzle in water, the welding nozzle is moved to the electromagnetic station and the hardened spatter droplets are pulled off magnetically.  
           [0009]    Another measure utilized to prevent spatter accumulation or to at least make spatter removal easier are anti-spatter compounds. These compounds can be liquid, gel, or an aerosol spray. When placed on the welding nozzle, the anti-spatter agent will act as a barrier between the molten droplets of metal and the welding nozzle to either prevent or weaken the bond to the welding nozzle after the molten metal droplets cool. Use of an anti-spatter compound generally slows the accumulation of spatter on the welding nozzle and makes for the easier removal of any spatter that accumulates on the welding nozzle. However, the usefulness of the anti-spatter compounds is limited in that unless applied before each weld, the anti-spatter compound will be consumed with successive welds, thereby requiring frequent shutdowns of the welding operation to manually apply fresh anti-spatter compound to the welding nozzle. Each stop makes the cycle time longer, and also requires an operator to manually apply the anti-spatter compound. Generally, the use of anti-spatter compounds in this manner has had minimal beneficial effects due to the labor-intensive nature of the application in any manufacturing setting.  
           [0010]    Welding contact tip is another significant cause of downtime on a welding operation. As a contact tip is used, it wears out due to arcing and abrasion. Friction and/or conductivity between the continuous electrode and the passage for the electrode in the contact tip causes the passage in the welding nozzle to become out of round and enlarged, which, in turn, permits the continuous electrode to move around in an uncontrolled manner within the passage. Such action eventually causes inaccuracy in the weld and eventually requires that the contact tip be replaced. To prevent or postpone this wear on the contact tip, feeders have been developed to feed the continuous electrode to the contact tip in a defined manner, because some contact between the electrode and the contact tip has been found to bear on the repeatable accuracy of the weld. Lubricants can also be applied to the continuous electrode to reduce the function between the continuous electrode and the contact tip.  
         SUMMARY OF THE INVENTION AND ADVANTAGES  
         [0011]    Various methods and/or systems are disclosed for providing an improved welding system and/or method that substantially improves the length of time of continuous operation for an automated welding system between maintenance shutdowns. One of the disclosed method steps or system elements provides for dipping a welding nozzle or tip and a portion of its related diffuser into a bath of fluid each time the automated welding system moves through a welding cycle. A product that may best accomplish this step or element is also disclosed.  
           [0012]    Another method step or system element may include the removal of spatter accumulation via an electromagnetic field that magnetically pulls the spatter without direct contact with the nozzle or diffuser. A further disclosed method step or system element includes lubrication of the continuous electrode used for welding, and may include a step prior to lubrication that involves cleaning the continuous electrode prior to adding lubricant. The steps may vary as to whether or not they are included, or in what sequence, in accordance with such factors as the type of material used for the tip, the feeder used, the type of continuous electrode used, the type of spatter removal system to be used, the welding apparatus used, the welding environment (such as the inert gases used), and the welding application, i.e., what material is being welded to what material, and other factors. In each system or combination of method steps disclosed, however, a significant increase in time of continuous operation between maintenance shutdowns has occurred, providing significant cost savings and higher productivity for the same machine. Products for implementing the systems and/or methods are also disclosed, as well as a product that will hold or combine various products as needed for a selected system and/or method.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
         [0014]    [0014]FIG. 1 is a perspective view of an automated welding system;  
         [0015]    [0015]FIG. 2 is a top view of the automated welding system of FIG. 1;  
         [0016]    [0016]FIG. 3 is a schematic view showing a continuous electrode, lubricating device, feed mechanism, welding nozzle, and the fluid bath apparatus as used in FIG. 1;  
         [0017]    [0017]FIG. 4 is a perspective view of the fluid bath apparatus mounted to a common bracket along with an electromagnetic spatter removal system as shown in FIG. 1;  
         [0018]    [0018]FIG. 5 a  is a cross sectional view of the fluid bath apparatus having a release agent included in the fluid;  
         [0019]    [0019]FIG. 5 b  is a cross sectional view of the fluid bath apparatus having no release agent included in the fluid;  
         [0020]    [0020]FIG. 6 is a cross sectional view of a metal welding nozzle;  
         [0021]    [0021]FIG. 6 a  is a cross sectional view of a nonmetal welding nozzle;  
         [0022]    [0022]FIG. 7 is a flow diagram outlining possible methods or systems of using the various components of the automated welding system;  
         [0023]    [0023]FIG. 8 a  is a cross sectional view of the fluid bath apparatus having a cooling system, according to an embodiment of the present invention;  
         [0024]    [0024]FIG. 8 b  is a top view of the fluid bath apparatus having a cooling system, according to another embodiment of the present invention;  
         [0025]    [0025]FIG. 8 c  is a cross sectional view of a torch chiller, according to an embodiment of the present invention;  
         [0026]    [0026]FIG. 9 a  is a view of a net for use with the fluid bath apparatus, according to an embodiment of the present invention;  
         [0027]    [0027]FIG. 9 b  is a cross sectional view of the net of FIG. 9 a , the fluid bath apparatus, and a magnetic device, according to an embodiment of the present invention;  
         [0028]    [0028]FIG. 10 a  is a cross sectional view of the fluid bath apparatus with a brush, according to an embodiment of the present invention;  
         [0029]    [0029]FIG. 10 b  is a top view of the brush of FIG. 10 a , according to an embodiment of the present invention;  
         [0030]    [0030]FIG. 10 c  is a top view of the brush of FIG. 10 a , according to another embodiment of the present invention; and,  
         [0031]    [0031]FIG. 11 is a cross-sectional view of the fluid bath apparatus with a brush and a magnetic device, according to an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0032]    Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, with particular reference to FIG. 5, an apparatus  10  for providing a bath  12  of a fluid to an automated welding system  14  is shown at  10 . The apparatus  10  includes a port  16  for the adaptation of a feed container  17  of fluid  18 , a reservoir  20  which is accessible to atmosphere, and a passageway  22  for communication between said feed container  18  and said reservoir  20 . The port  16  is preferably comprised of a connection between a threaded spout  15  to the feed container  17  containing the fluid  18  and a mated threaded inlet  19  to the passageway  22 . The apparatus  10  further provides means for maintaining the fluid bath  12  at a constant level within the reservoir  20  until the feed container  18  is exhausted. The relationship between the reservoir  20  and the feed container  18  is such that the apparatus  10  provides a balance between the surface tension of the fluid within the reservoir  20  and in contact with the atmosphere against the head created by the feed container  18  in communication with said passageway  22 . This relationship allows the level of the fluid bath  12  within the reservoir  20  to be maintained at a constant level as long as additional fluid remains within the feed container  18 . As the fluid bath  12  within the reservoir  20  is used, the volume of the fluid bath  12  within the reservoir  20  is replenished via the passageway  22  between the reservoir  20  and the feed container  18 . Additionally, a level sensor  11  may be used to detect a low level within the fluid bath  12 . If a low level is detected, then the welding system  14  may be shut down.  
         [0033]    With reference to FIG. 3, an example method of using the apparatus  10  to increase the duty cycle of an automated welding system  14  is shown. The automated welding system  14  includes a torch  25 .  
         [0034]    In one embodiment, the torch  25  includes a front end  26 . The front end  26  includes a nozzle  30 , a gas diffuser  32 , and a contact tip  34 . The torch  26  is connected to a robot  36 . A conduit  31  is also coupled to the torch  25  for supplying material to the torch  25 , e.g., gas, water, and a continuous electrode (see below).  
         [0035]    The method includes the steps of using a continuous electrode feeder device  24  to feed the continuous electrode  26  to and through the contact tip  34 , applying a friction reducing agent to the continuous electrode  26  as it is fed by said feeder device  24  to said contact tip  34 , dipping said front end  28  into a fluid bath  12  contained within said reservoir portion  20  of said apparatus  10  following a welding cycle, and utilizing a spatter removal device, such as an electromagnetic spatter removal system  54 , to remove spatter from said front end  28 . The continuous electrode feed mechanism  24  is used to insure that the continuous electrode  26  is consistently and smoothly feed to the contact tip  34 , and the friction reducing agent is applied to increase the feedability of continuous electrode  26  into and through the contact tip  34 . The friction reducing agent is preferably applied by means of a continuous electrode lubricator  50  having an applicator  70  fed via a wicking action from a reservoir  72 , which can be disposed in a housing  76 , having a inlet passageway  78  and an outlet passageway  80 . The housing  76  is preferably disposed between the feeder  24  and the supply container  82  (or source) for the continuous electrode  26 . A cleaner may also be applied to the continuous electrode  26  utilizing a similar device (not shown) located adjacent the continuous electrode lubricator  50 .  
         [0036]    As discussed above, in one embodiment, each torch  25  has a front end  28  which may be comprised of a nozzle  30 , a gas diffuser  32 , and a contact tip  34 . Alternatively, the front end  28  could include a flux core wire continuous electrode, a gasless wire tube and/or a nozzle. The flux core wire continuous electrode includes chemicals that produce the gas.  
         [0037]    The torch  25  is mounted to the robot arm  36  in a conventional manner. The gas diffuser  32  is connected to a source of preferable inert gas. Holes  33  in the gas diffuser  32  distribute the gas into the welding nozzle shroud  30  to control the welding environment at the weld.  
         [0038]    With reference to FIG. 6 or  6   a , contact between the contact tip  34  and the continuous electrode  26  is desirable for stability and repeatability of electrode feed, but will cause the feed hole  35  in the contact tip  34  to become out of round or enlarged at some point, thereby requiring more frequent replacement of the contact tip  34 , if high abrasiveness and arcing exist. Use of the friction reducing agent on the continuous electrode  26  will help maintain conductivity between the continuous electrode  26  and the contact tip  34 , which increases the life of the contact tip  34  for repeatable welding of the parts to be welded.  
         [0039]    For metal welding nozzles, the fluid bath  12  consists of a release agent, a solution of water and a release agent, or water. The release agent is used to prevent liquefied spatter that is deposited on the front end  28  of the torch  25  from forming a strong bond. Additionally, by quenching the front end  28  of the torch  25  in the fluid bath  12  between welding cycles, the front end  28  is repeatedly heated and cooled. The unequal rates of expansion and contraction of the spatter and the components of the front end  28  also work to remove the spatter from the front end  28 . The fluid bath  12  including the release agent is kept at a cool temperature in order to facilitate the hardening of the liquefied spatter. The temperature of the fluid bath  12  is dependent on the amount of time which the front end  28  of the torch  25  is immersed within the release agent. The temperature of the fluid bath  12  including the release agent must be cool enough to cause the liquid spatter to completely harden within the amount of time that front end  28  of the torch  25  is immersed. Typically, a release agent must be used when a welding nozzle  30  composed of metal is utilized due to the high strength bonding which occurs between the spatter and the metal nozzle  30 . The release agent is necessary to insure that the bonding between the front end  28  and the spatter is inhibited sufficiently to allow the spatter to be removed without damaging the front end  30 .  
         [0040]    Typically, as shown in FIG. 5, the front end  28  is dipped into the fluid bath  12  so that the surface  13  of the fluid bath  12  is disposed adjacent the holes  33  of the gas diffuser  32 , e.g., ¼ inch, so that no fluid enters the inside of the gas diffuser  32  via the diffusion holes  33  at any time.  
         [0041]    After the front end  28  has been dipped within the fluid bath  12  including the release agent, the front end  28  is then removed from the fluid bath  12  and positioned at its next station above a spatter removal system  54 . In one embodiment, the spatter removal system  54  is an electromagnetic spatter removal system  54 . The spatter must be completely hardened in order for the electromagnetic spatter removal system  54  to work correctly. The electromagnetic spatter removal system  54  uses magnetic fields to attract the spatter and pull the spatter from the front end  28 , such as that described above and shown in U.S. Pat. No. 4,838,287. This process step or system element will not work on spatter that is still liquefied. In one embodiment, the steps or elements of dipping the front end  28  within the fluid bath  12  including the release agent and subsequently utilizing the electromagnetic spatter removal device  54  are performed periodically each time the automated welding system 14 cycles a predetermined number of times.  
         [0042]    A different example method or system of using the fluid bath apparatus  10  to increase the duty cycle (i.e., on duty, between shutdowns) of an automated welding system  14  includes the steps or elements of using a continuous electrode feed mechanism  24  to feed the continuous electrode  26  to a contact tip  34  of a front end  28   a  of a torch  25 , applying a friction reducing agent to the continuous electrode  26  as it is fed through the feed device  24  to the contact tip  34 , dipping the front end  28   a  into a fluid bath  12  contained within said reservoir portion  20  of said apparatus  10  following a welding cycle (preferably where the surface of the fluid bath is disposed approximately ¼ inch from the holes  33  of the gas diffuser  32 ), and utilizing an electromagnetic spatter removal system  54  to remove spatter from said front end  28   a . In place of the metal nozzle  30 , however, a ceramic nozzle  30   a  is utilized. A ceramic welding nozzle  30   a  is more resistant to bonding of the spatter, thereby making the spatter removal easier. The inherent resistance to bonding displayed by the ceramic welding nozzle  30   a  makes the use of a release agent in the fluid bath  12  unnecessary. Therefore, instead of dipping the front end  28   a  into a fluid bath  12  of water and a release agent, the front end  28   a  is dipped into a fluid bath  12   a  consisting of only water. Just as with the release agent, the water only fluid bath  12   a  must be kept at a temperature which will allow the spatter to completely harden upon the front end  28   a  prior to utilizing the electromagnetic spatter removal system  54 .  
         [0043]    An additional example method of using the fluid bath apparatus  10  to increase the duty cycle of an automated welding system  14  includes only using the steps or elements of using a continuous electrode  26  feed mechanism to feed the continuous electrode  26  to a contact tip  34 , dipping said front end  28  into a fluid bath  12  contained within the fluid bath  12  of said fluid bath apparatus  10  following a welding cycle, and utilizing an electromagnetic spatter removal system  54  to remove spatter from said front end  28 . As previously discussed, the method can be practiced using a front end  28   a  having a nozzle  30   a  made from ceramic materials rather than metal and dipping the front end  28   a  within a fluid bath  12   a  of only water rather than a release agent to harden the spatter deposited on the welding tip  28   a . Alternatively, if a metal nozzle  30  is used, a release agent plus water is recommended.  
         [0044]    An additional example method of using the fluid bath apparatus  10  to increase the duty cycle of an automated welding system  14  includes the steps of using a continuous electrode feed mechanism  24  to feed the continuous electrode  26  to a contact tip  34 , dipping said front end  28  into a fluid bath  12  of said apparatus  10  following a welding cycle, and using a scraper or brush to remove the hardened spatter from the front end  28 . An impact device or a reamer may be other alternatives to remove the hardened spatter from the front end  28 . As previously discussed, the method or system can be practiced using a metal welding nozzle  30  and a fluid bath  12  including a release agent (or a solution of a release agent and water), or a ceramic welding nozzle  30   a  and a water fluid bath  12   a  to harden the spatter deposited on the welding nozzle  30  or  30   a , respectively. Although the electromagnetic spatter removal system  54  is not utilized in the present method, the release agent or water must still be maintained at a temperature which will facilitate the complete hardening of the spatter deposited on the welding nozzle  30  or  30   a , respectively. Removal of the spatter by scraping, brushing, reaming, or impacting does involve some manual labor, but the removal process has been found to be more efficient than those previously known, particularly when the spatter is completely hardened by the dipping of the front end  28  or  28   a  in the fluid bath  12  or  12   a , respectively. The steps or elements of dipping the front end  28  or  28   a  within the fluid bath  12  or  12   a  and subsequently removing the hardened spatter by brushing, scraping, reaming, or impacting the hardened spatter from the front end  28  or  28   a  are performed periodically at shutdown subsequent to each time the automated welding system 14 cycles a predetermined number of times. This method will improve the amount of time between shutdowns, but is not recommended to be as significant as the other methods and/or systems described above.  
         [0045]    Referring to FIGS. 1 and 2, an automated welding system utilizing the fluid bath apparatus  10  is shown at  14 . Referring to FIG. 3, a schematic-is shown which details the path of the continuous electrode  26  as it is fed from a spool through a continuous electrode lubricator  50  to the contact tip  34 , FIGS. 3 and 4 illustrate the mounting of the fluid bath apparatus  10  via bolt fasteners or similar fasteners onto a bracket  100  along with the electromagnetic spatter removal system  54 , similarly mounted with bolt fasteners or similar fasteners. As shown in FIG. 4, this bracket  100  is then affixed to a stand  102  via suitable fasteners (or may be fastened by welding or any other desired type of fastening that will retain its fastening in the environment in which the robot is maintained). The stand  102  is placed in a suitable location, as shown in FIG. 4, to be reached by the robot arm  36  for placement of the front end  28  or  28   a  at an appropriate time in the cycle.  
         [0046]    With reference to FIGS. 1 and 2, the stand  102  is preferably placed within the automated welding system  14 , but away from the area  108  in which welding is performed. For example in the illustrated embodiment, the stand  102  is disposed at a location approximately 90 degrees clockwise from the working area  108  as viewed from above. At should be noted that 90 the location of the stand  102  is dependent upon the application and may be placed at a location other then 90 degrees from the working area  108 . The fluid bath apparatus  10  and the electromagnetic spatter removal system  54  are placed in sequence on the stand  102  so that one is less than 90 degrees clockwise from the work area  108  as viewed from above and the other is more than 90 degrees clockwise from the work area  108  as viewed from above, so that the operation steps or elements can be sequential, if so desired.  
         [0047]    Returning to FIG. 4, in one embodiment, the bath  12  includes a bleeder apparatus  84  coupled to the reservoir  20 . The bleeder apparatus  84  includes a bleeder line  86  coupled to the reservoir  20  by a coupler  88  at one end and to an overflow container  90 . The bleeder apparatus  84  is adapted to catch any overflow from the reservoir  20  to maintain fluid level within the reservoir  20  at the fill line  13   a . The overflow is held in the overflow container  90  and may be emptied into the fluid container  17 .  
         [0048]    Referring to FIG. 7, a flow chart is shown which illustrates the possible methods or systems of use as described above. As shown, the flow chart begins with a continuous electrode feed mechanism  24  that may be used to feed the continuous electrode  26  from a spool to the contact tip  34 . A continuous electrode lubricator  50  may be located immediately after the spool to apply lubricant to the continuous electrode  26 . The lubricant will reduce friction as the continuous electrode  26  is fed to the contact tip  34 , and will reduce friction between the contact tip  34  and the continuous electrode  26  as the continuous electrode  26  passes through the contact tip  34 . Reduced friction and increased conductivity between the contact tip  34  and the continuous electrode  26  will reduce the amount of wear on the contact tip  34 , thereby increasing the life of the contact tip  34 . As shown in FIG. 7, the use of a continuous electrode lubricator  50  is optional, although it is preferable, but the method can be practiced without the continuous electrode lubricator  50  at an improved efficiency, but less than the efficiency with the use of the lubricator  50 .  
         [0049]    The welding nozzle  30 ,  30   a  can be made of either metal or ceramic material. If the welding nozzle  30  is made from metal, then the welding nozzle  30  is preferably dipped within a fluid bath  12  consisting of a release agent or a solution of water and a release agent. The release agent is used to prevent liquefied spatter that is deposited on the front end  28  from forming a strong bond to the surfaces of the front end  28 , and is kept at a cool temperature in order to facilitate the hardening of the liquefied spatter as described above.  
         [0050]    If the welding nozzle  30   a  is made from a non-metal material, then the welding nozzle  30   a  is dipped within a fluid bath  12   a  of only water if it is a carbon nozzle. If the nozzle  30   a  is a ceramic nozzle, it need not be dipped other than if the spatter needs to be cooled, in which case some improvement over other uses of ceramic nozzles can be maintained. Thus, with ceramic nozzles this step is optional. The inherent resistance to bonding displayed by the carbon or ceramic welding nozzle  30   a  makes the use of a release agent less effective. Therefore, instead of dipping the front end  28  into a fluid bath  12  of water and a release agent, the front end  28   a  is dipped into a fluid bath  12   a  consisting of only water. Just as with the fluid bath  12  including the release agent, the fluid bath  12   a  of water must be kept at a temperature which will allow the spatter to completely harden upon the welding tip  28   a . The fluid bath apparatus  10  is used to present the fluid bath  12   a  to the front end  28   a  in a manner that the front end  28   a  can be dipped within the solution as described above.  
         [0051]    After the front end  28  or  28   a  has been dipped within the fluid bath  12  or  12   a  (or otherwise as indicated in FIG. 7 as to ceramic nozzles), then the front end  28  or  28   a  is positioned so that any spatter which has accumulated upon the front end  28  or  28   a  can be removed by either an electromagnetic spatter removal system  54 , by brushing, reaming, scraping, or impacting (such as with a hammer), using ultrasonic, or other force, the spatter from the front end  28  or  28   a . The electromagnetic spatter removal system  54  uses magnetic fields to attract the spatter and pull the spatter from the front end  28  or  28   a . If the electromagnetic spatter removal system  54  is not used, then any spatter that has accumulated upon the front end  28  or  28   a  can be removed manually by either scraping, brushing, reaming or otherwise impacting the spatter from the front end  28  or  28   a . The steps of dipping the front end  28  or  28   a  within the release agent or water and subsequently utilizing the electromagnetic spatter removal device  54  or scraping, reaming, brushing or otherwise impacting the spatter from the front end  28  or  28   a  are performed periodically each time the automated welding system 14 cycles a predetermined number of times.  
         [0052]    With reference to FIGS. 8 a  and  8   b , in one aspect of the present invention, the bath  12  includes a cooling system  42 . Heat from the front end  28  or  28   a  is transferred to the fluid  18  within the bath  12 . The cooling device  42  helps to eliminate heat from fluid  18  within the bath  12 . Thus, the bath  12  may be smaller relative to the front end  28  or  28   a.    
         [0053]    With specific reference to FIG. 8 a , in one embodiment, the cooling system  42  includes a solid state cooling element  44 , such as a Peltier Device, within the reservoir  20 . A Peltier Device is a solid state thermoelectric module which acts as a heat pump.  
         [0054]    With specific reference to FIG. 8 b , in another embodiment, the cooling system  42  includes an element  46  wrapped around or in contact with at least a portion of the reservoir  20 . The element  46  may be cooled with a refrigerant, such as freon or liquid nitrogen or other cooled liquid. The element  46  includes one or more tubes or passageways  48  through which the refrigerant flows. The element  46  may be outside the reservoir  20 , as shown, or inside the reservoir  20 . Apparatus for cooling refrigerants and flowing the refrigerant through tubes are well known in the art and are therefore not further discussed.  
         [0055]    With reference to FIGS. 9 a ,  9   b , and  9   c , in another aspect of the present invention, the electromagnetic spatter removal system  54  includes a magnetic device  52  disposed within the fluid  18  in the reservoir  20 . In one embodiment, the magnetic device  51  is a magnet disposed within the bath torch  12 . In another embodiment, the magnetic device  52  is an electromagnetic coil device adapted to be energized by the electromagnetic spatter removal system  54  when the front end  28  or  28   a  is inserted into the bath  12 . Energization of the electromagnetic coil device  52  creates a magnetic field. The magnetic field created by energization of the electromagnetic coil or the magnetic field created by the magnet operates to remove spatter from the front end  28  or  28   a.    
         [0056]    A wire basket or net  56  is adapted to be inserted into the bath  12  to catch or contain the spatter removed from the front end  28  or  28   a . The basket  56 , in one embodiment, is composed of stainless steel. In an alternate embodiment, the basket  56  is composed of plastic. The basket  52  is designed to catch the spatter removed from the nozzle  28  by the electromagnetic spatter removal system  54 . The basket  56  includes a handle  58  by which the basket  56  may be removed from the reservoir  20  and emptied. The basket  56  also includes a lip  58   a  which rests along the top edge of the reservoir  20 . The basket  56  may be rigid or collapsible.  
         [0057]    In the illustrated embodiment, the electromagnetic coil device  52  includes a coil  52   a  wrapped about a base  52   b . A pair of leads  60  connects the coil  52   a  to a charging circuit  62  of the electromagnetic spatter removal system  54 . The base  52   b  is connected to a support structure  64  which supports the electromagnetic coil device  52  such that the device  52  in below the fill line  13   a  of the reservoir  20 . The support structure  64  includes a plurality of arms  64   a  which extend away and in a direction up (in FIG. 9 b ) from the base  52   b . The arms  64   a  are adapted to rest on top of the basket  56  and thereby removable position the electromagnetic coil device  52  within the reservoir  20 .  
         [0058]    In one embodiment, the coil  52   a  and the leads  52   b  are electrically insulated, e.g., coated or sheathed in insulating plastic or rubber. In another embodiment the fluid  18  within the reservoir  20  is non-conducting.  
         [0059]    In operation, when the front end  28  or  28   a  is inserted into the bath  12 , the electromagnetic spatter removal system  54  energizes the coil  52   a  via the charging circuit, thereby, creating a magnetic field which acts to remove spatter from the front end  28  or  28   a . The spatter is contained within the basket  56  and can thereafter be removed from the bath  12 .  
         [0060]    With reference to FIGS. 10 a ,  10   b , and  10   c , in another embodiment the bath  12  includes a brush  66  within the reservoir  20 . The brush  66  may be composed of stainless steel. The brush  66  is positioned such that the front end  28  or  28   a  is inserted into the brush  66  when inserted into the reservoir  20 . The brush  66  is used to remove spatter from the front end  28  or  28   a  when the front end  28  or  28   a  is inserted therein. The brush  66  includes a plurality of bristles  66   a . In one embodiment, as shown in FIG. 10 b , the bristles  66   a  are in a circular pattern. In another embodiment, as shown in FIG. 10 c , the bristles  66   a  are in a donut shaped pattern. The donut shaped pattern corresponds to the shape and dimensions of the nozzle  28 .  
         [0061]    Returning to FIG. 10 a , in one embodiment the brush  66  is coupled to the bottom of the reservoir  20  via a bracket  66   b . In another embodiment, the brush  66  is coupled to the bottom of the basket  56 . As above, the basket  56  may be removed to remove the spatter from the reservoir  20 . The brush  66  and basket  56  combination may be used with or without the electromagnetic coil device  52  of FIGS. 9 a - 9   c . If the brush  66  is used with the electromagnetic coil device  52 , the brush  66  may be connected either the basket  56  or the base  52  or support structure  66  (see FIG. 11).  
         [0062]    With reference to FIG. 8 c , in another aspect of the present invention, a torch chiller or cooler  110  may be utilized to cool the front end  28  of the torch  25  to remove spatter from the front end  28 . The torch cooler  110  may be use used independently or in combination with the other spatter removal devices. In one embodiment of the present invention, the torch cooler  110  contains a cooling material  112  which may be in the form of a fluid (liquid or gas) or solid. Examples of liquids that may be suitable include, but are not limited to, oil, a mixture of oil and water, anti-freeze solutions (such as those containing ethylene glycol and propylene glycol), and/or any suitable fluid which may be used to cool the torch. Suitable gases include inert gases such as nitrogen gas. Cooling material  112  in the form of solids may be in pellet form and may include dry ice or other suitable material.  
         [0063]    The cooling material  112  is within a container  114  which has an aperture  116  for insertion/removal of the front end  28  of the torch  25 . The container  114  may also include a closeable second aperture  118 . A filter or screen  122  may be placed within the second aperture  120 . A flush device  122  may be coupled to the container  114  at the second aperture  120 . The flush device  122  includes a valve (not shown) for opening and closing the second aperture  120  and releasing the material from the container  114 .  
         [0064]    The torch cooler  110  may also include a cooling element  124 , such as a Peltier Device. The cooling element  124  is used to cool the cooling material  112 . Alternatively, if the material  112  is a fluid, the cooling element  124  may remove the fluid from the container  114 , cool it, and pump it back to the container  114 .  
         [0065]    In still another aspect of the present invention, the fluid bath  12  includes a torch cleaner. The nozzle  30 ,  30 A, of the welding torch  25  may be made of various materials, such as a ceramic, copper, brass, or chrome. A suitable cleaner for the nozzle  30 ,  30 A is chosen. The cleaner in the fluid bath  12  acts to clean the nozzle  30 ,  30 A from its end up until the point at which it is dipped into the fluid bath  12 . This allows a visual indication of how far the nozzle  30 ,  30 A is being dipped into the fluid bath  12 . As a visual indication, a person does not need to enter the work area, and thus, requiring that work being performed by halted, to confirm that the nozzle  30 ,  30 A is being dipped into the fluid bath  12 .  
         [0066]    The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.