A continuity sensor determines continuity between welding electrodes by detecting a change in a voltage of a sensed tracer signal across the electrodes from a time when a weld cycle is initiated to a time when the electrodes contact material to be welded. As the electrodes are brought together with low force, the continuity sensor detects changes in the sensed voltage level exceeding a threshold thereby representing continuity and enables the welder to apply the higher welding force. However, if the continuity sensor does not detect a change in the voltage signal, then the welder will not apply the full welding force, thereby preventing pinch-point injury to the operator. The digital continuity sensor reestablishes a baseline for detecting the change in voltage with every new weld cycle such that the digital continuity sensor is not subject to changing voltages or changes in the welder configuration.

A continuity sensor determines continuity between welding electrodes by detecting a change in a voltage of a sensed tracer signal across the electrodes from a time when a weld cycle is initiated to a time when the electrodes contact material to be welded. As the electrodes are brought together with low force, the continuity sensor detects changes in the sensed voltage level exceeding a threshold thereby representing continuity and enables the welder to apply the higher welding force. However, if the continuity sensor does not detect a change in the voltage signal, then the welder will not apply the full welding force, thereby preventing pinch-point injury to the operator. The digital continuity sensor reestablishes a baseline for detecting the change in voltage with every new weld cycle such that the digital continuity sensor is not subject to changing voltages or changes in the welder configuration.

A collet assembly including an actuator and a collet connected to the actuator. The collet assembly is adapted to be installed on a welding electrode holder having an electrode. The collet is moveable by the actuator from an advanced position, in which the collet is adapted to grip a fastener such as a welding rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable the electrode to engage the fastener for welding to a work piece, and the collet is adapted to release the fastener.

A collet assembly including an actuator and a collet connected to the actuator. The collet assembly is adapted to be installed on a welding electrode holder having an electrode. The collet is moveable by the actuator from an advanced position, in which the collet is adapted to grip a fastener such as a welding rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable the electrode to engage the fastener for welding to a work piece, and the collet is adapted to release the fastener.

A device and method for monitoring and correcting the position and orientation of an operating device (2) with respect to a piece (P). A measuring device (5) including a plurality of sensors (505) connected to the operating device is used to measure through contactless technology the distances of the sensors from a surface () of the piece along respective directions (l, r, s) having given orientations. The sensor measurements are compared to predetermined desired values and the position of the operating device (2) is selectively changed to maintain a desired positional relationship between a main operative axis (X1) of the operative device and operation axis (X2) defined by the surface of the piece.

A device and method for monitoring and correcting the position and orientation of an operating device (2) with respect to a piece (P). A measuring device (5) including a plurality of sensors (505) connected to the operating device is used to measure through contactless technology the distances of the sensors from a surface () of the piece along respective directions (l, r, s) having given orientations. The sensor measurements are compared to predetermined desired values and the position of the operating device (2) is selectively changed to maintain a desired positional relationship between a main operative axis (X1) of the operative device and operation axis (X2) defined by the surface of the piece.

An example apparatus to monitor a welding-type system includes: a test signal generator configured to output a test signal to a monitored circuit; and a lock-in amplifier configured to: receive a reference signal based on the test signal; measure a leakage current in the monitored circuit based on the reference signal; and generate an output signal representative of the leakage current.

In the present invention, while a welding current is applied with respect to a laminate body comprising thick metal plates and thin metal plates, a first welding pressure (F1) with respect to the laminate body from an upper tip contacting the metal plate and a second welding pressure (F2) with respect to the laminate body from a lower tip contacting the metal plate are changed relative to each other. Specifically, F1<F2 in a first step which is an initial period of welding, F1=F2 in a second step which is an intermediate period of welding, and F1>F2 in a third step which is a final period of welding.

A method and an apparatus detects pressure changes at servo gun tips of a robotic welding system having a servo gun with a movable tip and an opposed fixed tip configured to weld a part. The method and apparatus observe a tip deflection value and convert the value to a current pressure value using a pressure estimator. The current pressure value is compared to a benchmark pressure value to detect any difference.

An apparatus includes a housing, a mechanism and a sensor. The housing may be configured to receive a weld head. The mechanism may be attached to the housing and configured to convert a position of a location pin relative to the housing into an angular rotation. The sensor may be coupled to the mechanism and configured to generate a value representative of the position of the location pin based on the angular rotation.