Systems and methods are provided for exchanging electrode tips, e.g., electrode tips used in resistance spot welding, and disposing of used/unusable electrode tips. Used/unusable electrode tips may be collected, e.g., while within an assembly line. Such used/unusable electrode tips may be routed to a receptacle(s) reside outside the assembly line. Accordingly, disposing or removing of the used/unusable electrode tips can be accomplished without stopping the assembly line, and decreasing any chance for safety events.

A resistance point welding apparatus for fixing a turbulence installation body to an inner wall of a steam generator pipe, having a welding head, which is introduced into the pipe and includes a lance having an electrically conductive material, a point welding electrode, which projects out of the lance in the radial direction, an effective element and an insulation body, which is opposite the point welding electrode in the radial direction and is moved by the effective element, is provided. The lance is tapered at a defined distance from the welding head end such that the insulation body and the point welding electrode press the turbulence installation body against the inner wall of the pipe when the effective element is activated. When a welding stream is impressed on the lance, a point-like welding stream flows via the point welding electrode to a counter electrode arranged outside the pipe.

A resistance point welding apparatus for fixing a turbulence installation body to an inner wall of a steam generator pipe, having a welding head, which is introduced into the pipe and includes a lance having an electrically conductive material, a point welding electrode, which projects out of the lance in the radial direction, an effective element and an insulation body, which is opposite the point welding electrode in the radial direction and is moved by the effective element, is provided. The lance is tapered at a defined distance from the welding head end such that the insulation body and the point welding electrode press the turbulence installation body against the inner wall of the pipe when the effective element is activated. When a welding stream is impressed on the lance, a point-like welding stream flows via the point welding electrode to a counter electrode arranged outside the pipe.

Provided is an articulated welding robot that includes an articulated arm in which a plurality of arm parts are linked via a drive shaft. A welding wire is disposed along the articulated arm. In at least one of the arm parts a depression is formed that forms a hollow on the inner side of the arm. At least a portion of the welding wire is accommodated in the depression.

Provided is an articulated welding robot that includes an articulated arm in which a plurality of arm parts are linked via a drive shaft. A welding wire is disposed along the articulated arm. In at least one of the arm parts a depression is formed that forms a hollow on the inner side of the arm. At least a portion of the welding wire is accommodated in the depression.

A method of resistance spot brazing a workpiece stack-up that includes a first thin-gauge steel workpiece and a second thin-gauge steel workpiece. The method includes several steps. A first step involves applying a filler material to a surface of the first thin-gauge steel workpiece. A second step involves bringing a surface of the second thin-gauge steel workpiece to adjoin the filler material. A third step involves clamping a first welding electrode and a second welding electrode on the first and second thin-gauge steel workpieces and over the filler material. A fourth step involves passing electrical current between the first and second welding electrodes and hence through the filler material. And a fifth step involves terminating passage of the electrical current in order to establish a brazed joint between the first and second thin-gauge steel workpieces.

A method of resistance spot brazing a workpiece stack-up that includes a first thin-gauge steel workpiece and a second thin-gauge steel workpiece. The method includes several steps. A first step involves applying a filler material to a surface of the first thin-gauge steel workpiece. A second step involves bringing a surface of the second thin-gauge steel workpiece to adjoin the filler material. A third step involves clamping a first welding electrode and a second welding electrode on the first and second thin-gauge steel workpieces and over the filler material. A fourth step involves passing electrical current between the first and second welding electrodes and hence through the filler material. And a fifth step involves terminating passage of the electrical current in order to establish a brazed joint between the first and second thin-gauge steel workpieces.

A method of resistance spot welding a workpiece stack-up that includes a first steel workpiece and a second steel workpiece. The method includes several steps. The first steel workpiece can have a first surface coating. One step involves applying a filler metal to a surface of the first steel workpiece. Another step involves bringing a surface of the second steel workpiece to adjoin the filler metal. Yet another step involves clamping a first welding electrode and a second welding electrode on the first and second steel workpieces. And another step involves passing electrical current between the first and second welding electrodes and hence through the filler metal. And yet another step involves terminating passage of the electrical current in order to establish a weld joint between the first and second steel workpieces.

A method of resistance spot welding a workpiece stack-up that includes a first steel workpiece and a second steel workpiece. The method includes several steps. The first steel workpiece can have a first surface coating. One step involves applying a filler metal to a surface of the first steel workpiece. Another step involves bringing a surface of the second steel workpiece to adjoin the filler metal. Yet another step involves clamping a first welding electrode and a second welding electrode on the first and second steel workpieces. And another step involves passing electrical current between the first and second welding electrodes and hence through the filler metal. And yet another step involves terminating passage of the electrical current in order to establish a weld joint between the first and second steel workpieces.

A welding cell for a resistance spot welding, its use for resistance spot welding, and a welding method performed therewith are disclosed. The welding cell includes a system for implementing resistance spot welding technology, a data collecting system, a system for improving efficiency of data collection, and a processing, monitoring, and control system. The welding cell includes a data transmission priority manager for adjusting digit capacity, transmission rate and transmission frequency of the digitized signal, separately, for signals of each sensor, and a digital twin controller, which, based on the digitized signal, provides a control signal to the control unit for controlling the electromechanical actuators and moving the electrodes of the welding cell. The welding cell provides for resistance spot welding with predictable and controllable quality, increased performance and reduced requirements to the computing unit performance of the welding cell, and reduced costs for equipping the welding cell.