Patent Publication Number: US-2018029156-A1

Title: Discharge Welding System

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     I hereby claim benefit under Title 35, United States Code, Section 119(e) of U.S. provisional patent application Ser. No. 62/368,425 filed Jul. 29, 2016. The 62/368,425 application is currently pending. The 62/368,425 application is hereby incorporated by reference into this application. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable to this application. 
     BACKGROUND 
     Field 
     Example embodiments in general relate to a discharge welding system for discharge welding a welding member such as a stud to a weld surface such as a battery terminal or strap. 
     Related Art 
     Any discussion of the related art throughout the specification should in no way be considered as an admission that such related art is widely known or forms part of common general knowledge in the field. 
     A secondary battery is a device consisting of one or more electrochemical or electrostatic cells, hereafter referred to collectively as “cells”, that can be charged electrically to provide a static potential for power or released electrical charge when needed. The cell is basically comprised of at lease one positive electrode and at least one negative electrode. One common form of such a cell is the well-known secondary cell packaged in a cylindrical metal can or in a prismatic case. Examples of chemistry used in such secondary cells are lithium cobalt oxide, lithium manganese, lithium iron phosphate, nickel cadmium, nickel zinc, and nickel metal hydride. Other types of cells include capacitors, which can come in the form of electrolytic, tantalum, ceramic, magnetic, and include the family of super and ultra capacitors. Such cells are mass produced, driven by an ever-increasing consumer market that demands low cost rechargeable energy for portable electronics. Energy density is a measure of a cell&#39;s total available energy with respect to the cell&#39;s mass, usually measured in Watt-hours per kilogram, or Wh/kg. Power density is a measure of the cell&#39;s power delivery with respect to the cell&#39;s mass, usually measured in Watts per kilogram, or W/kg. 
     In order to attain the desired operating voltage level, cells are electrically connected in series to form a battery of cells, what is typically referred to as a battery. In order to attain the desired current level, cells are electrically connected in parallel. When cells are assembled into a battery, the cells are often linked together through metal strips, straps, wires, bus bars, etc., that are welded, soldered, or otherwise fastened to each cell to link them together in the desired configuration. 
     Secondary batteries are often used to drive traction motors in order to propel electric vehicles. Such vehicles include electric bikes, motorcycles, cars, busses, trucks, trains, and so forth. Such traction batteries are usually large format types, comprised of tens to hundreds or more individual cells. The cells are linked together internally and installed into a case to form the completed battery. 
     A common method of electrical connection to the cells is welding. Several techniques are well known in the industry, including resistance spot welding, and laser welding. For some cells that have aluminum terminals, only laser welding is known to work to allow a proper connection to the terminal. Examples of such cells are lithium titanate cells manufactured by Toshiba Corporation and sold under the trade name SCiB. Unfortunately laser welders are costly, usually $500,000 to several million dollars each. Conventional more cost effective resistance type spot welding techniques cannot form a proper bond to the aluminum terminals. 
     The mechanical fabrication industry uses a technique known as capacitive discharge stud welding. Stud welding is a technique of welding where a fastener or specially formed nut is welded onto another metal part, typically a base metal or substrate. The fastener can take different forms, but typically fall under threaded, unthreaded or tapped. The bolts may be automatically fed into a spot welder achieving high speed assembly. Weld nuts generally have a flange with small nubs that melt to form the weld. 
     Capacitor Discharge (CD) stud welding, using very short weld times, permits the welding of small-diameter studs to thin, lightweight materials. The weld cycle can be completed in 0.01 seconds on material as thin as 0.020″ (0.5 mm). These fast weld times minimize heat buildup, resulting in welds with very little distortion, discoloration, or burning. 
     In Gap CD stud welding, the stud is positioned above, not against, the workpiece. When the stud is released, it accelerates toward the workpiece. Simultaneously, an open-circuit voltage is applied to the gap. The ignition tip is vaporized and the pieces are melted and forced together to form the weld. 
     SUMMARY 
     An example embodiment is directed to a discharge welding system. The discharge welding system includes a power source which is electrically connected to both a clamp and a retainer such as a collet. The clamp is utilized to secure a conduction member such as a washer against a weld surface such as a battery terminal or strap. The retainer is utilized to removably retain a welding member such as a stud which is adapted to be welded to the weld surface. A weld actuator is adapted to lower the retainer such that the welding member contacts the conduction member to complete an electrical circuit as an electrical current is discharged by the power source. The welding member is welded to the weld surface by the electrical current discharge. 
     There has thus been outlined, rather broadly, some of the embodiments of the discharge welding system in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional embodiments of the discharge welding system that will be described hereinafter and that will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the discharge welding system in detail, it is to be understood that the discharge welding system is not limited in its application to the details of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. The discharge welding system is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Example embodiments will become more fully understood from the detailed description given herein below and the accompanying drawings, wherein like elements are represented by like reference characters, which are given by way of illustration only and thus are not limitative of the example embodiments herein. 
         FIG. 1  is an exploded perspective view of a discharge welding system in accordance with an example embodiment. 
         FIG. 2  is a side view of a discharge welding system in accordance with an example embodiment. 
         FIG. 3  is a side view of a discharge welding system with a battery in position in accordance with an example embodiment. 
         FIG. 4  is a side sectional view of a discharge welding system with a battery in position in accordance with an example embodiment. 
         FIG. 5  is a side sectional view of a discharge welding system with a battery in position and a conduction member clamped to the battery in accordance with an example embodiment. 
         FIG. 6  is a side sectional view of a discharge welding system lowering the weld actuator to weld a stud to a weld surface in accordance with an example embodiment. 
         FIG. 7  is a side sectional view of a discharge welding system after welding the stud to the weld surface with the weld actuator retracted accordance with an example embodiment. 
         FIG. 8  is a side sectional view of a discharge welding system welding a battery strap in accordance with an example embodiment. 
         FIG. 9 a    is a side sectional view of a discharge welding system prior to use in accordance with an example embodiment. 
         FIG. 9 b    is a side sectional view of a discharge welding system with the conduction member clamped to the weld surface in accordance with an example embodiment. 
         FIG. 9 c    is a side sectional view of a discharge welding system as the stud is being welded to the weld surface in accordance with an example embodiment. 
         FIG. 9 d    is a side sectional view of a discharge welding system after the stud has been welded to the weld surface in accordance with an example embodiment. 
         FIG. 10  is an exemplary block diagram of a discharge welding system in accordance with an example embodiment. 
         FIG. 11  is a flowchart illustrating electrically connecting the clamp and retainer to a power source in accordance with an example embodiment. 
         FIG. 12  is a flowchart illustrating preparation of object for welding in accordance with an example embodiment. 
         FIG. 13  is a flowchart illustrating an exemplary welding process in accordance with an example embodiment. 
         FIG. 14  is a flowchart illustrating removal of the object after welding has been completed in accordance with an example embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     A. Overview 
     An example discharge welding system generally comprises a power source  50  which is electrically connected to both a clamp  35  and a retainer  45  such as a collet. The clamp  35  is utilized to secure a conduction member  37  such as a washer against a weld surface  16  such as a battery terminal  13  or strap  14 . The retainer  45  is utilized to removably retain a welding member  48  such as a stud which is adapted to be welded to the weld surface  16 . A weld actuator  40  is adapted to lower the retainer  45  such that the welding member  48  contacts the conduction member  37  to complete an electrical circuit as an electrical current is discharged by the power source  50 . The welding member  48  is welded to the weld surface  16  by the electrical current discharge. Using such a configuration, the weld surface  16  itself need not be electrically connected to the power source  50 . This is useful where the weld surface  16  comprises an electrically isolated structure, such as a battery terminal  13 . 
     The methods and systems described herein may be utilized with a wide range of weld surface  16  and welding members  48  to provide a wide range of functionalities. The methods and systems disclosed herein are particularly well-suited for applications relating to batteries. For example, the weld surface  16  could comprise a battery terminal  13  as shown in  FIGS. 1-7  or a battery strap  14  which interconnects cells as shown in  FIG. 8 . The methods and systems described herein could be utilized to weld any high current conductors with any different types of materials. The welding members  48  may comprise studs, blocks, plates, or the like. The methods and systems described herein could be utilized to weld aluminum battery straps  14  with metal studs as shown in  FIG. 8 . 
     The welding system  10  may comprise a conduction member  37  adapted to contact a weld surface  16  and a welding member  48  adapted to be welded to the weld surface  16 . A clamp  35  is adapted to transfer an electrical current from a power source  50  to the conduction member  37 ; with the clamp  35  being electrically connected to the power source  50 . A retainer  45  adapted to transfer electrical current from the power source  50  to the welding member  48  is electrically connected to the power source  50 . The retainer  50  is adapted to removably retain the welding member  48  to be welded to the weld surface  16 . A weld actuator  40  may be provided to lower the welding member  48  to contact the conduction member  37  to weld the welding member  48  onto the weld surface  16  when the welding member  48  contacts the conduction member  37 . The weld surface  16  may comprise a battery terminal and the welding member  48  may comprise a stud. The conduction member  37  may comprise a washer. In some embodiments, the clamp  35  may comprise an anode connection and the retainer  48  may comprise a cathode connection. The retainer  45  may comprise a collet. A housing  20  may be positioned over the weld surface  16 . The clamp  35  may comprise a rectangular plate. The clamp  35  may also include an opening  36 ; with the welding member  38  being adapted to be driven through the opening  36  by the weld actuator  40 . 
     In an exemplary embodiment as shown in  FIGS. 2-7 , the discharge welding system  10  may comprise a housing  20  adapted to be positioned over a weld surface  16 , a conduction member  37  adapted to be positioned on the weld surface  16 , and a welding member  48  adapted to be welded to the weld surface  16 . A power source  50  is utilized to provide an electrical current. A clamp  35  adapted to transfer the electrical current from the power source  50  to the conduction member  37  is electrically connected to the power source  50 . A retainer  45  adapted to transfer electrical current from the power source  50  to the welding member  48  is adapted to removably retain the welding member  48  to be welded to the weld surface  16 . A weld actuator  40  connected to the housing  20  is adapted to lower the welding member  48  to contact the conduction member  37 , wherein the welding member  48  is adapted to be welded onto the weld surface  16  when the welding member  48  contacts the conduction member  37 . A clamp actuator  30  connected to the housing  20  is adapted to raise and lower the clamp  35 , wherein the clamp actuator  30  is adapted to lower the clamp  35  to retain the conduction member  37  against the weld surface  16 . 
     A method of discharge welding is disclosed, comprising the steps of electrically connecting a clamp  35  to a power source  50 , electrically connecting a retainer  45  to the power source  50 , securing a conduction member  37  against a weld surface  16  with the clamp  35 , removably securing a welding member  48  with the retainer  45 , adjusting the welding member  48  such that the welding member  48  contacts the conduction member  37 , and activating the power source  50  to direct an electrical current through the retainer  45 , the welding member  48 , the clamp  35 , and the conduction member  37  such that the welding member  48  is welded to the weld surface  16  by an electrical discharge. 
     B. Housing 
     As shown throughout the figures, a housing  20  may be utilized to position the actuators  30 ,  40  over the object  12 ; with the weld actuator  40  preferably being positioned directly above the weld surface  16  of the object  12 . In some embodiments such as shown in the figures, the object  12  may itself be removably connected to the housing  20  such that the object  12  will not move around during the welding process. This may improve accuracy and reduce the likelihood of welding errors. 
     The shape, size, and configuration of the housing  20  may vary in different embodiments. In the exemplary embodiment shown in  FIGS. 2-7 , the housing  20  may comprise a base  24  and a support  22  extending upwardly over the base  24 . The base  24  may be free-standing or may be connected, such as by bolts or the like, to a surface such as a table or work bench. The base  24  may include a depressed portion to receive the object  12  such as shown in  FIGS. 2 and 3 . The base  24 , and housing  20  overall, will preferably be sufficiently sturdy to prevent unwanted vibrations or movements during the welding processes described herein. 
     The housing  20  may also include a support  22  to which the actuators  30 ,  40  are connected such that the actuators  30 ,  40  are positioned over the object  12 . The support  22  may comprise various configurations, including different shapes, sizes, orientations, and the like. The support  22  may in some embodiments be height adjustable such that the positioning of the actuators  30 ,  40  may be adjusted to accommodate differently-sized objects  12 . 
     In an exemplary embodiment as shown in  FIGS. 2-7 , the support  22  may comprise a horizontal projection which extends over the position of the object  12 . The clamp actuator  30  will preferably be positioned at a horizontal offset with respect to the weld surface  16 . The weld actuator  40  will preferably be positioned directly above the weld surface  16  such that the welding member  48  may be vertically lowered to contact the weld surface  16  through the clamp  35 . 
     The actuators  30 ,  40  may be removably connected to the housing  20  in some embodiments. This allows the actuators  30 ,  40  to be removed for servicing or replacement. The support  22  may include openings through which the actuators  30 ,  40  extend in some embodiments. Preferably, the actuators  30 ,  40  are connected to the support  22  of the housing  20  such that their respective shafts  32 ,  42  extend downwardly from the support  22  such as shown in  FIGS. 5 and 6 . 
     C. Clamp 
     As shown throughout the figures, a clamp  35  is utilized to temporarily secure a conduction member  37  against the weld surface  16  of the object  12 . The clamp  35  may comprise various configurations, shapes, sizes, orientations, and the like. Thus, the configuration shown in the figures should not be construed as limiting on the scope of the present invention. 
     As best shown in  FIG. 1 , the clamp  35  may comprise a rectangular plate-like member having an opening  36 . It should be appreciated that the clamp  35  need not necessarily comprise a rectangular shape, as other shapes may be more suitable for specific objects  12  or weld surfaces  16 . In the figures, the clamp  35  comprises a rectangular plate; with a position near a first end of the clamp  35  being connected to a clamp actuator  30  and a position near a second end of the clamp  35  including the opening  36 . Various other configurations may be utilized for different embodiments. 
     The shape, positioning, size, and orientation of the opening  36  in the clamp  35  may vary in different embodiments to suit different conduction members  37  and/or welding members  48 . As best shown in  FIG. 1 , the opening  36  may comprise a depressed opening  36  having sloped sidewalls. Such an embodiment will naturally drive welding members  48  such as studs toward and through the opening  36 . 
     The clamp  35  will preferably be electrically connected to a power source  50  such as shown in  FIG. 10 . The manner in which the clamp  35  is electrically connected to the power source  50  may vary in different embodiments. In some embodiments, external conduits may be utilized to connect the clamp  35  to the power source  50 . In other embodiments, conduits may be internal to the housing  20 . In some embodiments, there may be intervening structures, devices, or the like electrically connected between the clamp  35  and the power source  50 . While  FIG. 10  illustrates the clamp  35  as comprising an anode connection, the reverse may be utilized in some embodiments; with the clamp  35  serving as a cathode connection. 
     As best shown in  FIGS. 5-8, 9   b ,  9   c , and  9   d , the clamp  35  is preferably lowered to press the conduction member  37  against the weld surface  16 ; with the conduction member  37  being sandwiched between the clamp  35  and the weld surface  16 . In some embodiments, the clamp  35  may be manually secured against the weld surface  16 , such as via a vice grip or the like. 
     As shown in  FIGS. 4 and 5 , the clamp  35  is adjustable between a first, raised position above a point near the weld surface  16  and a second, lowered position wherein the clamp  35  is pressed against the weld surface  16  to secure the conduction member  37  against the weld surface  16 . In the embodiment shown in  FIGS. 2-7 , a clamp actuator  30  is utilized to raise and lower the clamp  35 . 
     The clamp actuator  30  may comprise a linear actuator including a first shaft  32  which is adapted to be extended and retracted with respect to the base of the clamp actuator  30 . Various other types of weld actuators  30  may be utilized and thus the scope of the present invention should not be construed as limited to linear actuators. 
     In the embodiment shown in the figures, a first connector  34  is connected between the first shaft  32  and the clamp  35 . In some embodiments, the first shaft  32  of the clamp actuator  30  may be directly connected to the clamp  35 . The clamp  35  may be removably or fixedly connected to the first shaft  32  or first connector  34 . In some embodiments, the power source  50  may be electrically connected to the first connector  34  such that an electrical current flows through the first connector  34  to the clamp  35 . In other embodiments, the power source  50  may be electrically connected directly to the clamp  35 . 
     As shown in  FIGS. 5-7 , the clamp  35  may secure a conduction member  37  against a weld surface  16 . The conduction member  37  is adapted to facilitate conduction of current to the weld surface  16  during the weld process. The conduction member  37  may comprise various conductive materials such as metals. Electrical current will generally flow from the power source  50  through the clamp  35  to the conduction member  37  when welding. However, in some embodiments, the power source  50  may be directly connected to the conduction member  37 . 
     The shape, size, and configuration of the conduction member  37  may vary in different embodiments. In the figures, the conduction member  37  is illustrated as comprising a washer, such as a brass washer. In some embodiments, the conduction member  37  may be disposable as the conduction member  37  may be damaged during welding. 
     While the figures illustrate the conduction member  37  as being circular-shaped, it could comprise other shapes such as rectangular plates and the like. The conduction member  37  is generally pressed with force against the weld surface  16  by the clamp  35 . The conduction member  37  will generally include an opening to allow the welding member  48  to contact both the conduction member  37  and the weld surface  16 . 
     D. Weld Actuator 
     As shown throughout the figures, a retainer  45  may be utilized to removably retain the welding member  48  during portions of the welding methods described herein. The retainer  45  may comprise any device or structure adapted to removably secure the welding member  48  therein. The retainer  45  may comprise various configurations, shapes, sizes, orientations, and the like. Thus, the configuration shown in the figures should not be construed as limiting on the scope of the present invention. 
     As best shown in  FIG. 1 , the retainer  45  may in some embodiments comprise a collet. In other embodiments, the retainer  45  could comprise various clamps, brackets, or the like adapted to removably secure the welding member  48 . The retainer  45  will generally secure the welding member  48  until the welding member  48  has been welded to the weld surface  16  as described herein. The retainer  45  may vary in different embodiments to suit different types of welding members  48 . 
     The retainer  45  will preferably be electrically connected to the power source  50  such as shown in  FIG. 10 . The manner in which the retainer  45  is electrically connected to the power source  50  may vary in different embodiments. In some embodiments, external conduits may be utilized to connect the retainer  45  to the power source  50 . In other embodiments, conduits may be internal to the housing  20 . In some embodiments, there may be intervening structures, devices, or the like electrically connected between the clamp  35  and the power source  50 . While  FIG. 10  illustrates the retainer  45  as comprising a cathode connection, the reverse may be utilized in some embodiments; with the retainer  45  serving as a cathode connection. 
     As best shown in  FIGS. 6, 8, and 9   c , the retainer  45  is preferably lowered such that the welding member  48  therein contacts the conduction member  37  to weld the welding member  48  to the weld surface  16 . In some embodiments, the clamp  35  may be manually lowered to contact the conduction member  37 , such as via a vice grip, by hand, or the like. 
     As shown in  FIGS. 9 b  and 9 c   , the retainer  45  is adjustable between a first, raised position above conduction member  37  and the weld surface  16  and a second, lowered position wherein the welding member  48  within the retainer  45  contacts the conduction member  37  to weld the welding member  48  against the weld surface  16 . In the embodiment shown in  FIG. 6 , a weld actuator  40  is utilized to raise and lower the retainer  45 . 
     The weld actuator  40  may comprise a linear actuator including a second shaft  42  which is adapted to be extended and retracted with respect to the base of the weld actuator  40 . Various other types of weld actuators  40  may be utilized and thus the scope of the present invention should not be construed as limited to linear actuators. 
     In the embodiment shown in the figures, a second connector  44  is connected between the second shaft  42  and the retainer  45 . In some embodiments, the second shaft  42  of the weld actuator  40  may be directly connected to the retainer  45 . The retainer  45  may be removably or fixedly connected to the second shaft  42  or second connector  44 . In some embodiments, the power source  50  may be electrically connected to the second connector  44  such that an electrical current flows through the second connector  44  to the retainer  45 . In other embodiments, the power source  50  may be electrically connected directly to the retainer  45 . 
     As best shown in  FIG. 5 , a welding member  48  is removably secured to the retainer  45 . The welding member  48  is adapted to be discharge welded to the weld surface  16  upon contacting the conduction member  37 , such as by being lowered by the weld actuator  40 . The welding member  48  may comprise various conductive materials such as metals. Electrical current will generally flow from the power source  50  through the retainer  45  to the welding member  48  when welding. However, in some embodiments, the power source  50  may be directly connected to the welding member  48 . 
     The shape, size, and configuration of the welding member  48  may vary in different embodiments. In the figures, the welding member  48  is illustrated as comprising a stud. In other embodiments, the welding member  48  could comprise a plate, a block with an opening in it, a nut, or any other medium known to be suitable for welding to a weld surface  16 . 
     The welding member  48  may include a tip  49  as best shown in  FIG. 8 . When the power source  50  is discharged, the tip  49  will be vaporized and an arc will be formed. This arc melts the welding member  48  against the weld surface  16  such as shown in  FIG. 9 c   . The shape, size, configuration, and orientation of the tip  49  of the welding member  48  may vary in different embodiments. Any tip  49  known in the art to be useful for discharge welding may be utilized. 
     E. Operation of Preferred Embodiment 
     In use, the power source  50  may first be electrically connected so as to provide a current through the conduction member  37  and the welding member  48 . As shown in  FIG. 11 , an exemplary embodiment electrically connects the clamp  35  and the retainer to the power source  50 . The welding member  48  may be removably connected to the retainer  45  either before or after the power source  50  is electrically connected to the conduction member  37  and/or welding member  48 . 
     It should be appreciated that a wide range of power sources  50  may be utilized to provide an electrical current. Any power source  50  known in the art to generate an electrical current may be utilized. In an exemplary embodiment, the power source  50  may comprise a capacitor. The power source  50  may comprise a welding machine in some embodiments. 
     The manner in which the power source  50  is electrically connected to the clamp  35  and the retainer  45  may vary in different embodiments. The power source  50  may be electrically connected with the first connector  34  which itself is electrically connected with the clamp  35 . The power source  50  may be electrically connected with the second connector  44  which itself is electrically connected with the retainer  45 . Alternatively, the power source  50  could be directly electrically connected with the clamp  35  and retainer  45 . 
     An exemplary embodiment is illustrated in  FIG. 10  in which the positive connection of the power source  50  is electrically connected to the clamp  35  and the negative connection of the power source  50  is electrically connected to the retainer  45 . Other configurations may be utilized as this is merely an exemplary embodiment. 
     As shown in  FIG. 12 , an object  12  such as a battery may be secured to the housing  20 . In embodiments where the object  12  is not secured to the housing  20 , the object  12  may be positioned on a flat surface so that that inadvertent movement is minimized. The object  12  may be secured against a base  24  of a housing  20  as shown in  FIGS. 3-7 . Clamps, vices, brackets, or the like may be utilized to removably connect the object  12  to the base  24  of the housing  20 . In some embodiments, the base  24  will comprise a depressed portion in which the object  12  may sit without moving. This type of embodiment is useful where a specific sized object  12  is being utilized, such as a standard battery size. 
     The conduction member  37  is secured against the weld surface  16  on the object  12 . The conduction member  37  may be secured against the weld surface  16  by the clamp  35  as shown in  FIGS. 9 b , 9 c , and 9 d   . In an exemplary embodiment, the clamp actuator  30  may be activated so as to extend the first shaft  32  and lower the clamp  35  onto the conduction member  37  so as to secure the conduction member  37  against the weld surface  16 . 
     The welding member  48  may be removably secured to the retainer  45 . In the exemplary embodiment shown in  FIG. 5 , the welding member  48  comprises a stud which is removably secured within a retainer  45  comprising a collet. Various other configurations may be utilized for removably connecting the retainer  45  and the welding member  48 . The tip  49  of the welding member  48  will preferably extend downwardly from the retainer  45  so as to be able to contact the weld surface  16  through the clamp  35  and conduction member  37  when the welding member  48  is lowered. 
     As shown in  FIG. 13 , the welding member  48  is then adjusted, such as by lowering, to contact the conduction member  37 . The welding member  48  may be adjusted by a weld actuator  40  as shown in  FIGS. 6 and 9   c . The weld actuator  40  may be activated to extend the second shaft  42  and retainer  45  such that the welding member  48  within the retainer  45  contacts the clamp  35 . 
     As the welding member  48  nears the clamp  35 , the power source  50  may be activated to produce an electrical current directed through the retainer  45 , clamp  35 , welding member  48 , and conduction member  37  such as shown in  FIG. 10 . In some embodiments, the power source  50  may be activated prior to lowering the welding member  48 . 
     The welding member  48  is directed through the opening  36  of the clamp  35  to contact the conduction member  37 ; completing the electrical circuit. The tip  49  of the welding member  48  will be vaporized such that the welding member  48  melts against the weld surface  16 . 
     The electrical current will generally pass through the clamp  35  to the conduction member  37 . When the retainer  45  is lowered with the welding member  48  such that the welding member  48  contacts the conduction member  37 , an electrical circuit is completed and the electrical current will pass through the welding member  48  and retainer  45 ; arcing to dissolve the tip  49  of the welding member  48  and thus weld the welding member  48  to the weld surface  16 . 
       FIGS. 9 a -9 d    illustrate such a method being utilized to weld a welding member  48  comprised of a stud to a weld surface  16  comprised of a terminal  13  of an object  12  comprised of a battery.  FIG. 8  illustrates such a method being utilized to weld a welding member  48  comprised of a stud to a weld surface  16  comprising a strap  14  of an object  12  comprised of a battery. These are merely exemplary embodiments and should not be construed as limiting on the type of object  12  or weld surface  16 . 
     As shown in  FIG. 14 , after the weld is complete, the retainer  45  may then be raised away from the weld surface  16 , such as by activating the weld actuator  40  to retract the second shaft  42 . The weld member  48  will remain welded to the weld surface  16 . The clamp  35  may be raised from the weld surface  16 . The conduction member  37  will typically be damaged and may be disposed of. The object  12  may then be removed from the housing  20  or repositioned for further welds. 
     Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the discharge welding system, suitable methods and materials are described above. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. The discharge welding system may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect.