Patent Description:
A pedestal welding gun station is a fairly common robot cell element that incorporates a resistance welding gun in a position that makes it accessible to one or more industrial robots. The industrial robot is used to manipulate an assembly of sheet metal stampings for presentation to one or more pedestal-mounted welding guns, or other equipment in the robot cell.

In the resistance spot welding process, a pair of copper alloy electrodes squeeze together on overlapping metal sheet(s) at the location a resistance spot weld is desired. The face geometry of the spot welding electrodes is selected based on the workpiece material(s) and thickness, desired weld size, and other process factors such as heat balance, weld appearance, and the presence of coatings, adhesives, or sealants. After sufficient force has been applied to bring the surfaces to be welded into intimate contact, a precisely controlled electrical current is passed between the copper alloy electrodes so it causes heating in the workpiece to achieve the weld.

The face of electrodes are subjected to significant localized heating, mechanical forces, and material interactions. The result is chemical and physical changes that affect the electrical conductivity of the welding electrodes and the concentration of heating and force. Some compensation is usually provided by automatic adjustment of resistance welding control parameters. At some point, it becomes necessary to either refurbish the electrode face or replace the electrode.

Most prior art involves tools that are manually operated or accessed by a robot mounted resistance welding gun. Pedestal-mounted welding guns are sometimes fitted with tip dressers that swing into a maintenance position, which is in the path of the closing welding electrodes. When the robot performs material handling, the full range of electrode maintenance tools does not appear to have been previously considered.

<CIT> describes a device for removing electrode caps from a conical receptacle of a welding robot. This document discloses a cap extractor comprising a housing, a pair of arms rotatably mounted inside the housing via a pair of pins, biased by springs, and having teeth to engage a welding cap. A linear actuator rotates the arms. The housing itself is mounted on pneumatic cylinders which are mounted on spring elements.

The present invention is defined herein in accordance with the appended claims. According to an aspect of the present invention, a cap extractor for a welding gun includes a housing. Spaced apart disks are arranged in the housing, the spaced apart disks being affixed to one another by means of a spacer pin, the spaced apart discs further being floatingly supported inside the housing by means of springs. First and second arms are arranged between and mounted to the disks, the first and second arms pivotably secured with respect to one another by means of the spacer pin. Each of the first and second arms have teeth configured to engage a welding cap. The first arm, second arm and the disks are configured to float by deflecting the springs and thereby moving relative to the housing in first and second directions transverse to one another to ensure alignment between the teeth and the welding cap. An actuator is pivotally attached to the housing, the actuator operatively connected to the first arm to rotate the first and second arms along with the disks, the actuator configured to articulate relative to the housing during rotation of the first arm in the housing.

In a further embodiment, the springs are wave springs. Each wave spring is received in a recess of one of the disks. A collar is arranged between each disk and the housing to locate a respective wave spring relative to the housing.

In a further embodiment, a biasing spring is interconnected to the first and second arms to urge the first and second arms toward one another.

According to another aspect of the present invention, a method of removing a cap from a welding gun using the cap extractor of the aspect hereinabove includes receiving a welding cap having a centerline received between teeth of the first and second arms; floating the arms along the centerline and laterally relative to the centerline during the receiving step to permit alignment between the teeth and the welding cap; and twisting the welding cap from a welding gun.

In a further embodiment, the method includes the step of normally biasing the first and second arms toward one another. The receiving step separates the first and second arms.

In a further embodiment, one of the first and second arms abuts a stop to precede the receiving step. One of the first and second arms is spaced from the stop during the twisting step.

In a further embodiment, the first and second arms are supported between disks. The first and second arms include the step of the disks supported by springs. The floating step includes deflecting at least one of the springs.

In a further embodiment, the twisting step includes articulating the actuator relative to the housing and rotating the first and second arms relative to the welding gun.

A welding station <NUM> is schematically illustrated in <FIG>. One example station <NUM> includes a load fixture <NUM> that establishes the position of workpieces <NUM> at the entrance to the welding station <NUM>. The welding station <NUM> includes a robot <NUM>, which may be enclosed by a perimeter fence <NUM> for safety.

Workpiece <NUM> may be placed into the load fixture <NUM> by an operator or automation. The robot <NUM> may retrieve workpiece <NUM> from the load fixture <NUM> using robot end of arm tooling <NUM> that holds the workpiece in the desired orientation and configuration. A welding gun <NUM> is mounted to a base <NUM> and spot welds the workpiece <NUM>, for example.

The welding gun station is commonly employed within robot cells for both spot and projection welding. Such robot cells employ one or more material handling robots to manipulate the workpiece(s) instead of the heavy resistance welding gun. This enables the use of smaller, more agile, and less expensive robots to automate the process. This robot cell configuration is also useful when the process involves multiple resistance welding guns that may be different sizes, configurations, or orientations. Or it may enable the robot to manipulate a workpiece between a number of stations employing different processes necessary to complete an assembly. Processes could for example include metal working, coating application, arc welding, fastener welding, assembly, and inspection.

The fence <NUM> can provide isolation between the robot cell and the electrode maintenance station including a maintenance tool assembly <NUM> for removing, installing and/or dressing the welding gun electrodes. This barrier would prevent the process on one side from affecting the other. It would therefore permit operations such as manual electrode maintenance or replacing the electrode dispensers to occur without interrupting the robot cycle.

A maintenance tool assembly <NUM> is mounted to the base <NUM>. Periodically, the welding gun <NUM> may be pivoted in a rotational path R to bring the welding "electrodes", "tips" or "caps" of the welding gun <NUM> to the maintenance tool assembly <NUM> for replacement and/or dressing. While it is possible in alternative configurations to pivot the welding gun to position the electrodes for extraction or replacement, the disclosed configuration illustrated employs a simple longitudinal translation T to move the tools. This improves the repeatability, control, and sensing of the welding gun pivot operation. It keeps the welding gun stationary during the maintenance operation so there is little chance of accidental collisions or unintended motion while in the electrode maintenance position.

Referring to <FIG>, the maintenance tool assembly <NUM> includes a cap extractor <NUM> and cap dispenser <NUM> including first and second cap dispensers 30A, 30B. A cap dresser <NUM> is provided at an end of the maintenance tool assembly <NUM> opposite the cap extractor <NUM> such that the cap dispenser <NUM> is arranged therebetween. The described resistance welding gun is for resistance spot welding but aspects of the configuration could be applied to projection welding equipment used to affix components such as fasteners or spacers.

Generally, a typical sequence would be to present the electrode caps to the tip dressing station on a regular basis. The frequency depends on the welding conditions but may be for example every <NUM>, <NUM> or <NUM> welds. At that time the tip dresser would use cutters or forming tools to clean or restore the profile of the electrode cap tip so welding consistency can be maintained. After a number of these tip dressing cycles have been performed, it is necessary to replace the electrode cap with a new one. The replacement frequency may relate to the number of tip dressing cycles, a physical attribute such as electrode cap length, a welding performance indicator such as excessive or insufficient welding current, or feedback of weld discontinuities.

A conventional dressing station is included for periodic light cleaning and shaping of the electrode face(s). When dressing of the electrode is no longer appropriate, an electrode extractor and electrode dispenser can be employed to replace the electrode(s).

The resistance spot welding gun station is configured to facilitate the required electrode maintenance so there is minimal impact on production throughput. Electrode maintenance is frequently performed during the time the industrial robot is executing material handling (i.e., retrieving workpieces or delivering the completed weldment to the unload station) or another function such as in-line inspection. The described robotic welding cell module permits maintenance to be performed entirely manually, or with automation. The electrode maintenance tools are modular in nature so the system can be reconfigured depending on the business priorities and financial analysis.

The disclosed resistance welding gun is mounted on a pivot unit assembly that enables the welding electrodes to be presented to a location away from the production area. The pivot is operated by a pneumatic cylinder that rotates the welding gun between hard position stops. The pivot could also be operated by a servo drive or other mechanical or electrical system that facilitates accurate positioning of the welding electrodes. The resistance welding electrodes can be serviced when the robot is being utilized to perform the workpiece manipulation. This reduces the possibility the robot cell throughput will be affected by the electrode maintenance operation.

The number and position of maintenance tools can be established to suit the anticipated electrode maintenance frequency, production rate, or resistance welding cell configuration. The station could include no maintenance tools to start, where the pivoting mechanism is used alone to present the welding electrodes outside of the robot cell for manual maintenance or replacement. An automatic electrode cap dressing tool could be added for regular lightly cleaning and profiling of the welding face. Additional tooling stations could be added to provide the capability to reshape the welding face or to remove and replace a worn out electrode.

The maintenance tools are outside of the production space, which can improve access to the electrode maintenance tools for servicing (e.g., emptying chips from the dresser or reloading cap dispenser), put the electrode maintenance tools in a location that is safer or more accessible to the personnel that are necessary to maintain them, permit a configuration that allows servicing of the electrode maintenance tools while the welding equipment is performing a production sequence, and ensure the production cell is not contaminated with errant machining chips, coolant, or electrode caps.

Referring to <FIG>, the welding gun <NUM> includes first and second arms <NUM>, <NUM> carrying first and second electrode adapters <NUM>, <NUM>, respectively. An electrode cap <NUM> is mounted on each of the first and second electrode adapters <NUM>, <NUM>. The caps <NUM> may be identical or could have different sizes and shapes to suit the welding conditions. The base <NUM> is supported by a pedestal <NUM> arranged within the work area. The welding gun <NUM> is supported with respect to the base <NUM> by a pivot <NUM> that is rotated between first and second positions by a pivot cylinder <NUM>. The first and second positions may be <NUM>° from one another. The welding gun is shown in the working position in <FIG>. The spot welding gun is moved clear of the welding area by a simple and reliable pivoting motion, that also positions the welding electrodes within reach of the integrated electrode maintenance tools. At least part of the time required for the off-line electrode maintenance process can be conducted while the robot continues to perform a material handling function.

Referring to <FIG> and <FIG>, the cap extractor <NUM>, cap dispenser <NUM>, and cap dresser <NUM> are mounted to a plate <NUM> that is carried by a platform <NUM>. The plate <NUM> is slideably mounted to the base <NUM>, which may include numerous members secured to one another. This translation stage puts the desired maintenance tool in the required position to service the electrode(s), which may include lifting the tool between a lowered and raised position to service the lower and upper electrode respectively. The maintenance tool assembly <NUM> translates along a longitudinal direction T (<FIG>) between numerous positions to place the components of the maintenance tool assembly <NUM> in the desired position with respect to the caps <NUM>. The maintenance tool assembly <NUM> may also move in a vertical direction L (<FIG>) to lift and lower the maintenance tool assembly with respect to the caps <NUM> during maintenance. Because one electrode extractor can be used to remove either electrode cap, the translation stage incorporates the vertical lift so either the upper or lower electrode cap can be aligned with the electrode extractor. A bin <NUM> collects the used, extracted caps <NUM>.

<FIG> illustrate various positions of the maintenance tool assembly <NUM> with respect to the welding gun. Either or both of the first and second arms <NUM>, <NUM> of the welding gun <NUM> may open and close with respect to one another. In one example, one of the arms is fixed and the other arm articulates to open and close about the workpiece during welding operations. In another example, the first and second arms may both open and close about the workpiece. The maintenance tool assembly <NUM> lifts or lowers the maintenance tools with respect to the cap <NUM> and its relative position on the first and second arms <NUM>, <NUM>. In <FIG>, one of the caps <NUM> is inserted into the cap extractor <NUM>. The cap <NUM> is rotated with respect to its electrode which breaks the cap <NUM> free from the welding gun. With the cap extractor <NUM> disengaged from the cap <NUM> (by raising or lowering the maintenance tool assembly <NUM>), the cap <NUM> may be released by the cap extractor <NUM>, dropping the cap into the bin <NUM>.

Referring to <FIG> and <FIG>, the electrode adapter <NUM>, <NUM> without its cap <NUM> may be inserted into one of the cap dispensers 30A, 30B of the cap dispenser <NUM>. The first and second electrode adapters <NUM>, <NUM> are closed about the new cap to seat the cap firmly on the electrode in an interference fit. Both the caps <NUM> can be removed from the first and second electrode adapters <NUM>, <NUM> by the cap extractor <NUM> before installing new caps using the cap dispensers 30A, 30B. Alternatively, the cap may be removed from one electrode adapter <NUM>, <NUM> by the cap extractor and a cap installed onto it before repeating the process for the other electrode.

The new caps may be dressed by the cap dresser <NUM>, as shown in <FIG>. In the example, the caps are dressed simultaneously by closing the first and second electrodes about an aperture of the cap dresser <NUM>. The cap dresser <NUM> may also be used to periodically dress used caps before the need to replace the caps <NUM>.

A control system <NUM> is schematically shown in <FIG>. The system <NUM> includes an air source <NUM> that selectively supplies compressed air to various components via control valve <NUM> that are operated by a controller <NUM>. The air source <NUM> supplies to a cap extractor cylinder <NUM> of the cap extractor <NUM>, a maintenance tool assembly lift cylinder <NUM>, and translate cylinder <NUM> of the maintenance tool assembly <NUM> and the welding gun pivot cylinder <NUM>. Other types of actuators may be used instead of air cylinders, if desired.

The first and second cap sensors <NUM>, <NUM> (also shown in <FIG>) may be used to detect the presence or absence of a cap <NUM> during the maintenance procedure. One or more cap presence detectors <NUM> may be used with the first and second cap dispensers 30A, 30B to detect an improper orientation and fault of a cap <NUM> within the cap dispenser <NUM> (<FIG>).

The motor <NUM> of the cap dresser <NUM> is operated by the controller <NUM>. Additionally, the controller <NUM> may also be used to control and monitor the welding gun <NUM> during various welding gun operations, as indicated in block <NUM>, including tracking when the welding gun is in need of tip maintenance.

Referring to <FIG>, the platform <NUM> is slideably supportive with respect to the base <NUM> by a slide assembly <NUM>. The translate cylinder <NUM> moves the platform <NUM> with respect to the base <NUM> and the welding gun <NUM> supported thereon between various discrete longitudinal positions (shown in <FIG>) to align the desired components of the maintenance tool assembly <NUM> with respect to the electrodes and/or caps.

The plate <NUM> is supported with respect to the platform <NUM> by guide posts <NUM>. A lift cylinder <NUM> is arranged laterally between guide posts <NUM> and vertically between the platform <NUM> and plate <NUM>. The lift cylinder <NUM> raises and lowers the maintenance tool components to their desired positions.

The first and second cap sensors <NUM>, <NUM> may be used to detect the presence of a cap <NUM> subsequent to extraction by the cap extractor <NUM> and installation of a new cap by the first and second cap dispensers 30A, 30B. If a cap is absent when one should be installed or present when it should have been removed, a fault is indicated.

The cap extractor <NUM> is illustrated in more detail in <FIG>. The extractor cylinder <NUM> includes a cylinder body <NUM> housing a piston. The cylinder body is secured to a mounting plate <NUM>. A rod <NUM> is connected to the piston within the cylinder body <NUM> and extends through the mounting plate <NUM> to a clevis <NUM>.

The extractor cylinder <NUM> is mounted to a housing <NUM> by spaced apart pivot pins <NUM>, which enables the extractor cylinder <NUM> to articulate with respect to the housing <NUM> during operation. The housing <NUM> may include multiple housing portions 100A-100D, collectively referred to as "the housing <NUM>.

The housing <NUM> includes apertures <NUM> for receiving the end of an electrode adapter <NUM>, <NUM> with its cap <NUM>. Ends of collars <NUM> are arranged with the apertures <NUM>, and wave springs <NUM> are arranged concentrically about each collar <NUM>. A pair of spaced apart disks <NUM> have a recess that receives one side of the wave springs <NUM>.

First and second arms <NUM>, <NUM> are carried by the disks <NUM>. The first arm <NUM> has a hole <NUM> that receives a pin <NUM> securing the clevis <NUM> to the first arm <NUM>. The second arm <NUM> has an end <NUM> that is received in a channel <NUM> of the first arm. The first and second arms <NUM> and <NUM> are pivotably secured with respect to one another by a spacer <NUM> that spaces the disks <NUM> with respect to one another and ensures that they rotate together with respect to the housing <NUM>. Another spacer <NUM> is received within a slot <NUM> in the second arm <NUM>. In the example, three spacers <NUM> are circumferentially spaced with respect to one another and rotationally affix the disks <NUM> to one another.

A biasing spring <NUM> interconnects the first and second arms <NUM>, <NUM> to urge them toward one another, in turn, bringing complementary teeth <NUM> toward one another to engage the cap <NUM>. A stop <NUM> provided on the housing portion 100A limits the travel of the second arm <NUM> during rotation via a stop pin <NUM> carried thereon.

The wave springs <NUM> enable the disks <NUM> to float within the housing <NUM> better ensuring alignment with the teeth <NUM> and the cap <NUM>. That is, there is some flexibility provided by the wave springs <NUM> to enable the disk <NUM> and the associated first and second arms <NUM>, <NUM> to float both laterally and vertically. Thus, absolute precise alignment between the caps and the cap extractor <NUM> is not required for effective cap extraction.

The extraction jaw mechanism floats in a plane normal to the center axis of the jaws. This allows the central axis of the extractor jaws to move, if required, to be coincident with the axis of the electrode taper. This prevents a binding force between the taper surfaces that could otherwise be created during rotation when the two axis are not aligned. Increased surface friction due to binding may inhibit axial movement necessary to separate the electrode from the adapter. Such position variation may arise from inaccuracy of the positioner or by bending or deflection of the welding gun or its components. When the electrode is positioned by automation or an industrial robot, the electrode could be misaligned with the cap electrode extractor due to position teaching inaccuracy, positioning repeatability deviation, or deflection within the mechanical system.

The jaw mechanism floats in the direction of the taper axis. This permits the strain in the electrode and adapter tapers to aid in releasing the taper engagement. The intimate engagement of the tapers is maintained by stress on the material, which causes one or both of the components to deform. A female electrode cap taper for example will expand (stretch) slightly as its taper is engaged over the male taper of the electrode cap adapter. This strain applies a force on the two taper surfaces to lock them together. On a common ¾" (<NUM>) diameter female electrode, the distance between initial engagement and locking of the tapers may be <NUM>/<NUM>" (<NUM>). Mounting of the extractor jaw mechanism between the wave springs <NUM> provides the electrode cap the freedom to move in the direction of the taper axis. By permitting this movement, when the electrode cap is rotated to break the static friction between taper surfaces, the strain on the taper helps to urge the tapers apart. This ensures the electrode is consistently released from the adapter.

Since the cap extractor <NUM> is accessible from either side it is not necessary to change the welding gun orientation for a single tool to extract either the upper or lower electrode.

First, second, and third positions of the cap extractor are respectively illustrated in <FIG>. For better visualization, in <FIG>, the arcs A1 and A2 illustrate the path along which the pin <NUM> and stop pin <NUM> move during cap extraction. The spacer <NUM> interconnecting first and second arms <NUM>, <NUM> move along a circular path C with the rotation of the disks <NUM>. The "+" along these paths indicate the elements position in the first, second and third positions.

Referring to <FIG>, the extractor cylinder <NUM> is shown with the piston in a fully retracted position such that the first and second arm <NUM>, <NUM> are maximally spaced with respect to one another to better facilitate accommodating the cap into the cap extractor. In this position, the stop pin <NUM> engages the stop <NUM>. Once the cap <NUM> has been positioned between the teeth <NUM>, the extractor cylinder <NUM> begins to close from the first position shown in <FIG> to the second position shown in <FIG>, which more tightly clamps the teeth <NUM> about the cap <NUM>. In this second position, the stop pin <NUM> is spaced from the stop <NUM>.

Referring to <FIG>, the extractor cylinder <NUM> is actuated to a fully extended position in which the first and second arms <NUM>, <NUM> are further closed about the cap, finally releasing the cap <NUM> from its electrode adapter <NUM>, <NUM>. In this third position, the second arm <NUM> may engage one of the spacers <NUM>, which was located between the first and second arms. Subsequently, the extractor cylinder <NUM> is retracted, which returns the first and second arms <NUM>, <NUM> to the first position shown in <FIG>. In this position, once the electrode adapter <NUM>, <NUM> has been moved with respect to the cap <NUM>, the cap will simply drop into the bin <NUM> beneath.

The technique employed for extracting the electrode caps is simply a twisting motion to break the friction of the engaged tapers. When the cylinder advances, the serrated jaws of the extractor bite into the electrode cap to impart the rotation. The configuration of the jaw mechanism enables it to center to the electrode adapter taper, thereby ensuring the applied force is consistent even pressure on the serrations. Prior to the cylinder reaching the limit of rod extension, the cap will have been freed. When the cylinder retracts and the jaws reach the hard stops they will separate and allow the electrode cap to fall into the container provided. If cooling water is released when the cap is removed, it will also be captured by the bin <NUM>.

The first and second cap dispensers 30A, 30B are illustrated in more detail in <FIG>. In the example, the first cap dispenser 30A is in identical construction with respect to the second cap dispenser, only their orientation is different. Thus, the second cap dispenser 30B will be explained in further detail in connection with <FIG>.

The process of installing a new cap is as simple as closing the welding gun onto the electrode cap. After the friction fit tapers engage, opening the welding gun easily overcomes the sliding friction between electrode caps to remove the electrode cap from the dispenser. As soon as the space occupied by the electrode cap is clear another electrode cap will move towards the outlet.

The cap dispenser is configured for off-line refilling and quick exchange. The dispenser can be made to a standard length or the length necessary to accommodate the number of electrode caps required between the standard service intervals.

The dispenser is easily removed from its holder by pulling the spring loaded catch. The dispenser is easily serviced in a similar fashion by pulling the spring loaded catch. There is no cumbersome on-line dispenser loading or replacement process required so dispensers can be loaded off line. This also has the added advantage of easily enabling different electrode caps to be installed in the dispenser when required by a different workpiece or welding condition.

A sleeve <NUM> slideably receives a drawer <NUM> that houses the caps <NUM>. The drawer <NUM> includes a ramp <NUM> that selectively cooperates with a pin <NUM> carried by an end cap <NUM> mounted to the sleeve. The pin <NUM> may be spring loaded to bias the pin <NUM> inward to engage the ramp <NUM> when the drawer is fully inserted and seated with respect to the sleeve <NUM>. Alternatively, the pin <NUM> may be threadingly moved into and out of an engagement with respect to the ramp <NUM>. The dispenser is easy to load since the tray can be fully opened or partially opened for filling, depending on which method is easiest for a particular size and geometry of welding electrode.

Electrode caps are urged towards the outlet of the dispenser by a follower, which is pulled by a constant force spring. A spring assembly <NUM> is mounted to the sleeve <NUM> to urge a slide block <NUM> located within the drawer <NUM> in a direction that forces the caps <NUM> to a position beneath an aperture <NUM> in a plate <NUM>. In an example, the spring assembly <NUM> includes a spring housing <NUM> having first and second housing portions 148A, 148B. The spring housing <NUM> receives a drum <NUM> rotatable about a roller pin <NUM> that secures the housing portions 148A, 148B to one another. A clock spring <NUM> is affixed to the drum <NUM> at one end and to the slide block <NUM> at an opposite end by a fastener <NUM>. The clock spring <NUM> wraps about the drum <NUM> in a normally biased position. Thus, the slide block <NUM> is pulled leftward as illustrated in <FIG> to push the stack of caps <NUM> toward the aperture <NUM>.

The presence of the cap at the outlet is verified by a sensor, which confirms the straight side of the electrode cap skirt is tight against the stop. A through beam light sensor is provided to ensure there is a properly oriented electrode cap at the discharge point. A fiber optic through-beam light sensor is referenced, but other sensors can be employed. The sensor has the secondary function of verifying there is an electrode cap in the dispenser since the follower is configured so it will not operate or activate the electrode cap detection sensor.

Referring to <FIG>, the drawer <NUM> includes a hole <NUM> that may cooperate with the cap presence detector <NUM>, which may be a laser. If a cap <NUM> is oriented improperly such that the hole <NUM> is obstructed, a fault condition may be indicated requiring the cap dispenser to be serviced.

The disclosed arrangement uses a simple mechanical system to pivot the welding gun to move the electrodes out of the work area of the welding cell. Stand-alone electrode maintenance tools and simple translation stages achieve a total solution that is easy to expand, more economical, and easier to maintain. Because the maintenance tools do not have a footprint within the robot envelope, they do not affect or require any of the reach of the robot. The maintenance tools are not exposed to the hazards and contamination found within the welding cell. The robot cell is not exposed to the hazards and contamination that may occur at the maintenance tools. The maintenance tools may be made accessible for service while the robot is cycling.

The maintenance tools are moved to defined positions so there is no requirement for position variation compensation schemes, such as spring centered slides, which can contribute to erratic machining results in the prior art due to chattering.

Movement in the plane perpendicular to the taper axis minimizes the possibility a side force could be applied to the taper surfaces, which could inhibit the taper separation. Movement in the direction of the taper axis ensures the tapers can separate without the need for external force or movement.

The design includes a simple round orifice that is less sensitive to electrode geometry variation such as the diameter or surface condition of the electrode cap. It also does not rely on the accessible surface of the taper or of electrode. The design is much simpler than others which employ shafts, gears, cams, and motors. This reduces the cost and improves the operational reliability.

The linear dispensers can be made to accommodate a variety of electrode cap sizes. Spring loaded pins are employed to latch the linear dispenser into its holder and to retain the drawer in the closed position. Therefore, the functions of filling and replacing the dispenser may be easy accomplished independently.

Filling may be performed off line if desired. During filling, the dispenser can be held at an orientation that best exploits gravity to aid the process. The length of the exposed opening during loading can also be coordinated to minimize the opportunity for electrodes to tip over, if their geometry predisposes them to do so. The action of closing of the dispenser, applies spring pressure that will be used to urge the cap electrodes towards the opening.

Replacement of the dispenser can be performed to minimize interaction time or for convenience. It can also be done to change the electrode geometry if a changeover is performed to enable the robot cell to produce different weldments.

It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, and described, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated in the appended claims, and will still benefit from the present invention.

Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations.

Claim 1:
A cap extractor (<NUM>) for a welding gun (<NUM>) comprising:
a housing (<NUM>);
spaced apart disks (<NUM>) arranged in the housing (<NUM>), the spaced apart disks (<NUM>) being affixed to one another by means of a spacer pin (<NUM>), the spaced apart discs (<NUM>) further being floatingly supported inside the housing (<NUM>) by means of a pair of springs (<NUM>);
first and second arms (<NUM>, <NUM>) arranged between and mounted to the disks (<NUM>), the first and second arms (<NUM>, <NUM>) pivotably secured with respect to one another by means of the spacer pin (<NUM>), each of the first and second arms (<NUM>, <NUM>) having teeth (<NUM>) configured to engage a welding cap (<NUM>);
the first arm (<NUM>), second arm (<NUM>) and the disks (<NUM>) being configured to float by deflecting the springs (<NUM>) and thereby moving relative to the housing (<NUM>) in first and second directions transverse to one another to ensure alignment between the teeth (<NUM>) and the welding cap (<NUM>); and
an actuator pivotally attached to the housing (<NUM>), the actuator operatively connected to the first arm (<NUM>) to rotate the first and second arms along with the disks (<NUM>), the actuator configured to articulate relative to the housing (<NUM>) during rotation of the first arm (<NUM>) in the housing (<NUM>).