Material Positioner for Welding Apparatus and Method

Abstract

A material positioner can utilize characteristics of the material being welded to locate the material to be welded. In some embodiments, the material positioner has a voice coil actuator (VCA) for material positioning. In some embodiments, the VCA is sent a signal based on the characteristics of the material being welded and/or the type of weld being completed. In at least some embodiments, a single welder can be used over a wide range of materials. In some embodiments, end-uses that require components to be in generally mating engagement for further processing can benefit from a material positioner.

What is claimed is: 
     
         1 . A material positioner for use with a welder. 
     
     
         2 . The material positioner of  claim 1 , wherein said material positioner comprises:
 (a) a first fixture having a first material secured to said first fixture;   (b) a second fixture having a second material secured to said second fixture;   (c) a first positioning mechanism adapted to place said first material at a first starting point;   (d) a second positioning mechanism adapted to place said second material at a second starting point, said second starting point having said first and second materials in generally mating engagement, actuation of said second positioning mechanism generally forces said second material against said first material and locates said second material to a second position, and said second position having said first and second materials generally coalesced;   (e) a control unit adapted to send a signal to each of said first and second positioning mechanisms, and said signal adjustable based on characteristics of said first and second materials; and   (f) a heat generator adapted for welding said first and second materials to each other to produce a weld, wherein said second positioning mechanism is a voice coil actuator.   
     
     
         3 . The material positioner of  claim 2 , wherein continued actuation of said second positioning mechanism locates said first and second materials to a third position, said third position having said first and second materials generally cooled. 
     
     
         4 . The material positioner of  claim 3 , wherein said third position has said first and second materials transitioning from a molten state to a solid state. 
     
     
         5 . The material positioner of  claim 2 , wherein said signal is a voltage. 
     
     
         6 . The material positioner of  claim 5 , wherein said voltage has a magnitude based on said characteristics of said first and second materials. 
     
     
         7 . The material positioner of  claim 2 , wherein said signal is provided by an adjustable power supply. 
     
     
         8 . The material positioner of  claim 2 , wherein said signal is provided by a fixed power supply. 
     
     
         9 . The material positioner of  claim 2 , wherein actuation of said second positioning mechanism is adapted to provide a generally constant force between said first and second materials during said heat generator welding. 
     
     
         10 . The material positioner of  claim 2 , wherein said welding is resistance welding, spot welding, stud welding, friction welding, or energy beam. 
     
     
         11 . The material positioner of  claim 2 , wherein said weld is a butt joint or a lap joint. 
     
     
         12 . The material positioner of  claim 2 , wherein said first and second materials are solid wire, strand wire, rod-shaped, flat stock, pipe, or tubing. 
     
     
         13 . The material positioner of  claim 4 , wherein said signal is a voltage and wherein said voltage has a magnitude based on said characteristics of said first and second materials. 
     
     
         14 . The material positioner of  claim 13 , wherein said signal is provided by an adjustable power supply. 
     
     
         15 . The material positioner of  claim 13 , wherein said signal is provided by a fixed power supply. 
     
     
         16 . A method of positioning material for use with a welder. 
     
     
         17 . The method of  claim 16 , said welder comprising a first positioning mechanism, a second positioning mechanism, a first material having a first starting point, a second material having a second starting point and a second position, and a control unit adapted to send a first signal to said first and second positioning mechanisms, wherein said method comprises:
 (a) placing said first material at said first starting point;   (b) placing said second material at said second starting point;   (c) sending said first signal from said control unit to said second positioning mechanism, wherein said second positioning mechanism is a voice coil actuator;   (d) welding said first and second materials together; and   (e) placing said first and second materials in generally coalescent engagement.   
     
     
         18 . The method of  claim 17 , further comprising:
 (f) sending a second signal to said second positioning mechanism to return said second positioning mechanism to said second starting point, wherein said second signal is generally of reversed polarity from said first signal sent to said second positioning mechanism.