Electrode and method changing an electrode to a welding torch

Abstract

An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. The first truncated cone has a first truncated end and an opposing conical end. A working end portion includes a second truncated cone having a second truncated end. A constant length is defined between the opposing conical end and the second truncated end. The constant length is about 0.875 inch+/−0.001 inch. The elongated body is located between the seating end portion and the working end portion.

What is claimed is: 
     
         1 . An electrode comprising:
 an elongated body defining a longitudinal axis;   a seating end portion including a first truncated cone, wherein the first truncated cone has a first truncated end and an opposing conical end; and   a working end portion including a second truncated cone having a second truncated end;   a constant length defined between the opposing conical end and the second truncated end, wherein the constant length is about 0.875 inch+/−0.001 inch; and   the elongated body located between the seating end portion and the working end portion.   
     
     
         2 . The electrode as recited in  claim 1 , wherein the first truncated cone defines an included angle of about 45°. 
     
     
         3 . The electrode as recited in  claim 1 , wherein the second truncated cone defined an included angle of about 30°. 
     
     
         4 . The electrode as recited in  claim 1 , wherein the seating end surface is substantially planar and substantially perpendicular to the longitudinal axis. 
     
     
         5 . The electrode as recited in  claim 1 , wherein the working end surface is substantially planar and substantially perpendicular to the longitudinal axis. 
     
     
         6 . The electrode as recited in  claim 1 , wherein the seating end portion includes a circumferential surface and an angled surface located between the circumferential surface and the elongated body, the circumferential surface is located between the first truncated cone and the angled surface, and the angled surface defines an included angle of about 90°. 
     
     
         7 . An electrode comprising:
 an elongated body defining a longitudinal axis;   a seating end portion including a first truncated cone; and   a working end portion including a second truncated cone,   wherein the elongated body is located between the seating end portion and the working end portion.   
     
     
         8 . The electrode as recited in  claim 7  wherein the first truncated cone has an included angle of about 45°. 
     
     
         9 . The electrode as recited in  claim 7 , wherein the second truncated cone has an included angle of about 30°. 
     
     
         10 . The electrode as recited in  claim 7 , wherein the first truncated cone has a first truncated end and an opposing conical end, the second truncated cone has a second truncated end, a constant length is defined between the opposing conical end, and the second truncated end and the constant length is about 0.875 inch+/−0.001 inch. 
     
     
         11 . A welding torch assembly comprising:
 a mounting plate;   a welding torch mounted to the mounting plate, wherein the welding torch includes:   an adjustment track fixed to the mounting plate,   an adjustment body slidable relative to the adjustment track,   a torch body,   an electrode holder having a longitudinal axis,   an electrode including an elongated body defining a longitudinal axis, a seating end portion including a first truncated cone, a working end portion including a second truncated cone, wherein the elongated body is located between the seating portion and the working portion,   a retaining nut that secures the electrode in the electrode holder, wherein the electrode retaining nut contacts the angled surface of the seating end portion, and   a shield gas cup secured to the torch body that forms a welding arc to melt filler wire.   
     
     
         12 . The welding torch assembly as recited in  claim 11  wherein the first truncated cone of the seating end portion defines an included angle of about 45° and the electrode holder includes a truncated conical recess having an included angle of about 45°. 
     
     
         13 . The welding torch assembly as recited in  claim 11  wherein a seat of the retaining nut engages another angled surface of the seating end portion of the electrode. 
     
     
         14 . The welding torch assembly as recited in  claim 11  including an arc length defined between a point of the electrode at the working end portion and an upper surface of the filler wire, wherein the arc length is about 1.0 mm. 
     
     
         15 . The welding torch assembly as recited in  claim 11  wherein the adjustment track includes one of a groove and a protrusion and the adjustment body including the other of the groove and the protrusion, and the protrusion is receivable in the groove to allow the adjustment body to slide relative to the mounting plate to move the welding torch. 
     
     
         16 . The welding torch assembly as recited in  claim 11  including an adjustable fastener received in the adjustment slide that provides fine alignment between welding torch and the filler wire. 
     
     
         17 . The welding torch assembly as recited in  claim 11  wherein the torch body includes a pair of opposing slots that receive one of a pair of arms of a fixed docking station when a new electrode is installed in the welding torch. 
     
     
         18 . A method of changing an electrode of a welding torch comprising the steps of:
 automatically removing a gas shield cup from a welding torch;   automatically removing an electrode and an electrode retaining nut from the welding torch;   automatically installing a new electrode and a new electrode retaining nut on the welding torch; and   automatically replacing the gas shield cup on the welding torch.   
     
     
         19 . The method as recited in  claim 18  including the step of aligning slots on the welding torch with arms of a fixed docking station with a robot arm to secure the welding torch to the fixed docking station. 
     
     
         20 . The method as recited in  claim 18  wherein the step of automatically installing the new electrode on the welding torch includes applying a tightening torque of about 180 to about 200 N cm and the step of automatically replacing the gas shield cup on the welding torch includes applying a tightening torque of about 50 N cm.