Electric Connector Engaging a Welder to a Spot Welding Tool

Abstract

An electrical connector for removably engaging a welder to a spot welding tool having a first arm in a pivoting engagement to a second arm. The connector features an electrically conductive member engaged to or forming a powered translating shaft of a welder which is surrounded by a housing. The connector engages within a passage formed in a coupling to communicate forward and rearward movement and electric current to a first arm of a spot welding tool.

Claims

1. An electrical connector for removably engaging a welder to a spot welding tool having a first arm in a pivoting engagement to a second arm, comprising: a conductive member having a first end opposite a second end thereof; said first end of said conductive member engageable to a translating shaft of a welder; a coupling, said coupling configured at a first end thereof to form a connection to said first arm of said spot welder tool; said second end of said conductive member slidable to an engagement with a second end of said coupling; said translating shaft moveable in a first direction toward said coupling to thereby rotate said first arm to move a first electrode engaged thereto toward a second electrode engaged to said second arm, wherein electric current communicated from said welder through said conductive member to said coupling will energize said first electrode and said second electrode to form a spot weld on metal placed therebetween.

2. The electrical connector of claim 1, additionally comprising: an exterior surface of said conductive member having a tapered portion thereof; an interior surface of an interior passage extending into said second end of said coupling, having a tapered section thereof; and said engagement of said second end of said coupling to said second end of said conductive member positioning said tapered portion of said exterior surface of said conductive member in contact with said tapered section of said interior surface of said passage.

3. The electrical connector of claim 1, additionally comprising: said connection of said coupling at said first end thereof, being a rotational engagement with said first arm.

4. The electrical connector of claim 2, additionally comprising: said connection of said coupling at said first end thereof, being a rotational engagement with said first arm.

5. The electrical connector of claim 1, additionally comprising: said engagement of said second end of said conductive member with said second end of said coupling being a locked engagement.

6. The electrical connector of claim 2, additionally comprising: said engagement of said second end of said conductive member with said second end of said coupling being a locked engagement.

7. The electrical connector of claim 3, additionally comprising: said engagement of said second end of said conductive member with said second end of said coupling being a locked engagement.

8. The electrical connector of claim 4, additionally comprising: said engagement of said second end of said conductive member with said second end of said coupling being a locked engagement.

9. The electrical connector of claim 2, additionally comprising: a collar slidably engaged around an exterior surface of said coupling; at least one ball positioned within a ball passage, said ball passage communicating with said interior passage of said coupling; a biasing member biasing said collar toward said second end of said coupling to a locking position; an interior surface of said collar biasing said ball within said ball passage to a position having a portion of said ball projecting into said interior passage of said collar; an annular recess formed into said exterior surface of said conductive member; and a locked engagement formed by said portion of said ball projecting into said passage of said collar being positioned within said annular recess.

10. The electrical connector of claim 5, additionally comprising: a collar slidably engaged around an exterior surface of said coupling; at least one ball positioned within a ball passage, said ball passage communicating with said interior passage of said coupling; a biasing member biasing said collar toward said second end of said coupling to a locking position; an interior surface of said collar biasing said ball within said ball passage to a position having a portion of said ball projecting into said interior passage of said collar; an annular recess formed into said exterior surface of said conductive member; and said locked engagement formed by said portion of said ball projecting into said passage of said collar being positioned within said annular recess.

11. The electrical connector of claim 6, additionally comprising: a collar slidably engaged around an exterior surface of said coupling; at least one ball positioned within a ball passage, said ball passage communicating with said interior passage of said coupling; a biasing member biasing said collar toward said second end of said coupling to a locking position; an interior surface of said collar biasing said ball within said ball passage to a position having a portion of said ball projecting into said interior passage of said collar; an annular recess formed into said exterior surface of said conductive member; and said locked engagement formed by said portion of said ball projecting into said passage of said collar being positioned within said annular recess.

12. The electrical connector of claim 8, additionally comprising: a collar slidably engaged around an exterior surface of said coupling; at least one ball positioned within a ball passage, said ball passage communicating with said interior passage of said coupling; a biasing member biasing said collar toward said second end of said coupling to a locking position; an interior surface of said collar biasing said ball within said ball passage to a position having a portion of said ball projecting into said interior passage of said collar; an annular recess formed into said exterior surface of said conductive member; and said locked engagement formed by said portion of said ball projecting into said passage of said collar being positioned within said annular recess.

13. The electrical connector of claim 1, additionally comprising: said translating shaft of said welder being surrounded by a housing; and a connector for engaging said housing to said second arm of said welder.

14. The electrical connector of claim 2, additionally comprising: said translating shaft of said welder being surrounded by a housing; and a connector for engaging said housing to said second arm of said welder.

15. The electrical connector of claim 6, additionally comprising: said translating shaft of said welder being surrounded by a housing; and a connector for engaging said housing to said second arm of said welder.

16. The electrical connector of claim 8, additionally comprising: said translating shaft of said welder being surrounded by a housing; and a connector for engaging said housing to said second arm of said welder.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings which are incorporated in and form a part of this specification illustrate embodiments of the invention and together with the description serve to explain the principles of this invention.

[0028] FIG. 1 depicts a conventional C-type or X-type spot welder having first and second arms in a pivoted engagement for which the device is adapted to engage and depicts the conductive tapered member of the connector herein communicating through a housing which is engaged with one arm of the welder, where the tapered portion of the conductive member engages within a mirrored tapered recess of a coupling connected which is connected to the other of the two arms.

[0029] FIG. 2 shows a sectional view through the coupling with the conductive member in operative locked engagement therewith where the tapered circumferential portion of the conductive member is in contact with the tapered interior wall of the recess in the coupling and a plurality of balls are in biased engagement within the annular recess in the conductive member.

[0030] FIG. 3 shows the member in the locked engagement with the coupling as in FIG. 2 from an exterior view.

[0031] FIG. 4 is a sectional view along line 4-4 through FIG. 3.

[0032] FIG. 5 depicts the device of FIGS. 1-3 but moved to an unlocked connection by translating a spring biased ring to release the balls from the annular recess.

[0033] FIG. 6, is a sectional view along line 6-6 of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Referring now to the drawings of FIGS. 1-6, wherein similar parts of the invention are identified by like reference numerals. There is seen in FIGS. 1-2, the device 10 which provides an easy to engage and disengage, self locking electric connector, which is employable to communicate electric current when operatively connected to a conventional C-type or X-type spot welder 12.

[0035] As noted, such spot welders 12 conventionally have a first arm 14 which pivots in a rotational engagement with a second arm 16. In this rotational engagement the first arm 14 is electrically isolated from a second arm 16 such as with insulating washers and bushings formed of a polymeric material, which while not shown are well known in the art.

[0036] In operation of conventional spot welders 12, a first electrode 18 connected to the first arm 14 is translated into contact with the second electrode 20 engaged to the second arm 16 with metal therebetween, to form a spot weld. This is conventionally accomplished by the force from a motor or hydraulic driven member which translates back and forth to rotate the first arm 14 in its pivoting engagement 11 with the second arm 16. Such pivoting engagements 11 are conventionally accomplished, for example, by an axle communicating through an aperture in the second arm 16 and through a passage aligned with the aperture in the first arm 14. Insulating washers and bushings formed of polymeric or other dielectric material electrically separate the first arm 14 from the second arm 16 in such pivoting engagements 11.

[0037] The connector device 10 herein is adapted to engage with such spot welders 12 to provide the electric current necessary in their operation to form the spot weld. The connector device 10, because it is imparting force to the spot welder 12 to close the two electrodes to contact metal to be spot welded, is conventionally removably engaged to the moving arm, which as shown herein is the first arm 14 in the pivoting engagement 11 with a static second arm 16.

[0038] As seen in FIG. 1, an electrically conductive member 22, such as one formed from conductive metal such as copper or aluminum or another electrically conductive metal, forms one half of the connector device 10 herein. This conductive member 22 is configured at a connection end or second end to form a removable engagement to a electrically conductive coupling 24, which is engaged to the moving arm, which as shown herein is the first arm 14 to provide the movement to close the electrodes. As shown, the second end of the conductive member 22 engages with a coupling 24 which is in electrical engagement and operatively connected to the first arm 14 to rotate the first arm 14 and the engaged first electrode 18 toward the second arm 16 and second electrode 20.

[0039] In FIG. 2 can be seen another view of such an engagement to a conventional spot welder 12 component having a first arm 14 rotatable on and electrically isolated from a second arm 16. As shown, the conductive member 22 may be slidably engaged itself within a housing 26, or may be engaged to an existing laterally translating shaft on a resistance welder which translates within a housing 26. If formed to engage the translating shaft of existing resistance welders which are well known and have a electrically conductive translating shaft which slides axially within a housing 26 when triggered to do so, threads or other connective means at the first end can engage the two.

[0040] If formed as part of a resistive welder which has a housing 26, the conductive member 22 itself may form the translating shaft within the housing and be engaged to a power source of the welder. The conducting member in this mode will, thus, translate within the housing 26 when triggered to do so. The conductive member 22 is configured at a second end to engage a coupling 24 attached to a first arm of a spot welder 12. As such, what is meant by configured to engage a translating shaft of a welder is meant that the first end of the conductive member 22 may be connected to a translating shaft of the welder or form it.

[0041] The engagement of the housing 26 surrounding the conductive member 22 with the first arm 16 of the spot welder 12 is configured to position the conductive member 22 in alignment of the axis of the axis 45 of the conductive member 22 with the axis 47 of the coupling 24. A removable engagement is formed between the second end of the conductive member 22 and a coupling 24 engaged with a first arm 14 of a spot welder 12.

[0042] This engagement by a fastener such as the shown collar 13 on the second arm 16 also isolates the second arm 16 electrically from any electric current in the conductive member 22. The second arm 16 in the depicted configurations would conventionally be grounded. In this engaged position, such as is also shown in FIG. 3-4, the conductive member 22 communicates electric current when triggered to do so to the first arm 14 of the spot welder 12 for forming a spot weld in between the electrodes 18-20 when they are compressed on metal. The second arm 11 may be electrically grounded to allow completion of the circuit wherein metal placed between the first electrode 18 and second electrode 20 will be spot welded.

[0043] In a preferred mode of the device 10, the conductive member 22 is engaged within the housing 26 which surrounds it, and electrically isolates the second arm 16 connected thereto by a fastener such as the shown collar 13. The conductive member 22 is connected at a first end to a powered translation means such as a hydraulic ram, electric motor, or gear train, which may be triggered to communicate force to the conductive member 22 to translate toward or away from the coupling 24.

[0044] This back and forth translation of the conductive member 22 may be at a force moving toward the coupling 24 or away from the coupling 24, such that a force to close the gap between the electrodes 18 and 20 can be imparted, as well as a force to move them apart. This movement depends on which direction the powered translation means engaged to the conductive member 22 is activated. Thus, the conductive member 22 is configured at the first end to engage with such powered translator, which can be triggered to impart force toward and away from the coupling 24 during use, to both force the welder 12 closed and force it to reopen.

[0045] The second end of the conductive member 22 is shaped to engage with the coupling 24 in a locked engagement therewith, which holds the conductive member 22 locked to the coupling 24. Such a locked engagement is preferable because while force communicated to the conductive member 22 in a direction toward the coupling 24 will keep the two engaged, when that force is reversed, to power the welder 12 back to an open configuration without the lock the conductive member 22 would separate from the coupling 24. The coupling 24, in preferred modes, is in a pivoting connection 23 to the first member 14 such that it will conduct electricity once the conductive member 22 is energized. The pivoting connection 23, thus, will communicate electric current from the coupling 24 to the first arm 14 and the first electrode 18 once the conductive member 22 is energized.

[0046] As shown in FIG. 3-4, the device 10 herein is configured so the conductive member 22 has a tapered portion 30 sized and configured to engage in a self locking, electrically conductive engagement, within a passage 28 axially formed into a first end of the coupling 24. The second end of the coupling 24 is adapted for operative pivoting engagement 23 with the chosen arm of the C-type or X-type spot welder 12.

[0047] As noted and shown in FIGS. 3-4, depicting the conductive member 22 herein in a locked engagement with the coupling 24, this translating conductive member 22, such as shown in FIGS. 2 and 6, is insulated and electrically isolated from the surrounding housing 26. The surrounding housing 26 is configured for removable engagement to a fixed-position of one of the arms of the C-type or X-type spot welder 12, here shown as second arm 16. The housing 26 is configured to position and maintain the conductive member 22 axially aligned, when it translates under the force in either direction which is imparted to the first end thereof as noted above. The conductive member 22 is also adapted for engagement on the first end 21 thereof, with a source of high amperage electric current which is employed to achieve the spot weld such as an electric cable engaged therewith.

[0048] In between the first end and second end of the conductive member 22 is positioned a tapered portion 30 which preferably has a tapered exterior surface 41 which extends circumferentially around the conductive member 22. This circumferentially tapered surface 41 serves to maximize and form an electric contact area of the conductive member 22 against the surface of a tapered wall portion 29 of the passage 28, which is mirrored in size and shape and formed in the coupling 24.

[0049] An annular recess 36 formed into the exterior circumferential surface of the conductive member 22, is configured to frictionally engage with at least one and preferably a plurality of balls 38, which will bias and project into the passage 28 of the coupling 24 to a projecting position. The balls 38 are located in a ball passage 51 formed into the body of the coupling 24.

[0050] The balls 38 are biased to maintain this projecting position by a biasing member such as a spring 40 shown in FIGS. 3 and 6, which forces the ring 25 engaged around and sliding upon an exterior surface area 37 of the coupling 24, toward a contact with a first ledge 27. This first ledge 27 extends from the exterior surface of the coupling 24. With the ring 25 biased toward the first ledge 27, an annular slot 35 which has a diagonal wall 42 connecting to a linear wall 44 biases the balls 38 to the projecting position whereafter an interior surface area 39 of the ring 25 will hold the ball 38 to the projecting position of FIG. 4, with the ball 38 projecting into the passage 28 from its position within the ball passage 51. This contact of the ball 38 with the annular recess 36 forms the locked engagement of the conductive member 22 with the coupling 24 as shown in FIG. 4, for example. As noted herein, in this locked engagement the tapered portion 30 of the conductive member 22 is in full contact with the tapered wall 29 formed in mirrored shape within the collar.

[0051] In reaching this locked engagement shown in FIG. 4, from the unlocked engagement of FIG. 6, for example, the tapered portion 30 of the exterior surface of the conductive member 22, forms a ramp which extends to a planar or linear portion 31 of the exterior surface. This configuration has been found in experimentation to allow the ball to more easily roll on the tapered portion 30 and then settle into the annular recess 36, than a mode of the conductive member 22 without it.

[0052] Further, the ball 38 while in contact with the linear portion 31, may project into the annular slot 35 and contact the diagonal wall 42 of the annular slot 35, to hold the ring 25 spaced from any contact with the first ledge 27 as in FIG. 6. Consequently, this linear portion 31 which runs parallel to the axis 45 of the conductive member 22 is preferred as it provides for an easier engagement of the conductive member 22 into the passage 28.

[0053] In operation, when the conductive member 22 is pushed into the passage 28 of the coupling 24, the force of the balls 38 running up the formed ramp defined by the tapered wall portion 29 and across the linear potion 31, is sufficient to overcome the biasing force of the spring 40. This will force the balls 38 out of the way and concurrently slide the ring 25 in a direction away from the first ledge 27 when the ball 38 is forced against the diagonal wall 42 of the annular slot 35 in the ring 25. This action actuates an automatic sliding of the ring 25 away from the annular first ledge 27 to a position allowing the ball 38 to move along the tapered portion 30 and linear portion 21 of the exterior surface of the conductive member 22.

[0054] During this engagement process, as the conductive member 22 is translated by force into the passage 28, the balls 38 travel up the formed ramp of the tapered wall portion 29 to a peak and onto the linear potion 31, where they project a distance both into the passage 28 and into the annular slot 35 and against the diagonal wall 42 thereof. The balls 38 in this slightly projecting position, thereafter encounter and are biased into the annular recess 36, by the force of the spring 40 or other biasing member, biasing the ring 25 toward the first ledge 27.

[0055] In this fashion, the balls 38 are held in a biased engagement in the recess 36 formed annularly into the exterior of the conductive member 22. This projection and contact of one or a plurality of the balls 38 in the annular recess 36 forms a removable locked engagement of the conductive member 22 projecting within the passage 28 with the tapered portion 30 of the conductive member 22 in contact and electric communication with the tapered wall portion 29 of the passage 28. This locked engagement is maintained until released by sliding the ring 25, with sufficient force to overcome the biasing member such as the spring 40, in a direction away from the first ledge 27.

[0056] As noted, with the conductive member 22 in this removable engagement with the coupling 24, a force imparted to translate the conductive member 22 in either direction will cause movement of the arm engaged to the coupling 24. Thus, the force imparted to the conductive member 22, locked in engagement by the balls 38 to the coupling 24, is employable to close the arms of the spot welder 12 on a point on metal to spot weld that point. So engaged, the force of the conductive member 22 in a reverse direction is employable to open the arms and release such a contact with metal, to allow removal of the spot welder 12.

[0057] Additionally shown in FIGS. 4 and 6 are an internal passage 29 which may run axially through the conductive member 22. This passage 29 can be used to communicate cooling fluid to the spot welder 12 once the conductive member 22 is engaged with the coupling 24. A coolant passage 33 formed into the coupling 24 is in sealed engagement with coolant conduits formed in one or preferably both of the first and second arms of the spot welder 12, to thereby communicate cooling fluid to positions adjacent one or preferably both electrodes. Such provides cooling during use.

[0058] The device 10 shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present invention. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described, may be employed for providing a portable resistance welder multi-purpose attachment device in accordance with the spirit of this invention, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this invention as broadly defined in the appended claims. As such, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modifications, various changes and substitutions are intended in the foregoing disclosure, and will be appreciated that in some instance some features of the invention will be employed without a corresponding use of other features without departing from the scope of the invention as set forth in the following claims.