DESC:TECHNICAL FIELD
[001] The embodiments herein generally relate to a spot welding machine, more particularly but not exclusively to an apparatus and a method for dressing the electrode tips of a spot welding machine to a desired configuration without significant metal removal.

BACKGROUND
[002] A spot welder, which is generally used to weld vehicle panels, etc., is a resistance welder in which upper and lower electrode tips are positioned to press both surfaces of metal panels and apply electric current thereto so as to weld them. Broadly there exist two types of spot welders depending on pressure mechanisms. The two spot welders are, an air gun which employs a pneumatic cylinder as a pressure drive source, and a servo gun which employs a servo motor as a pressure drive source.
[003] Weld tips for resistance spot welding (RSW) becomes worn, deformed or contaminated over the course of repeated welding operations. The worn RSW electrode tips tend to produce welds of lower quality. To improve welding quality, it is important to periodically dress (remove metal to form desired shape) an electrode tip of the welding machine to maintain even welding spots of the electrode tip.
[004] Conventionally tip dressers have rotating cutters that are used for cleaning and reshaping electrode tips after use in production welding operations. Dressing process is performed on each electrode tip until the weld tips have returned to their original shape.
[005] Conventional resistance spot welding electrode dressers have limited control over the amount of material removed from each individual electrode face during the dressing process. This lack of control over metal removal during the dressing process can result in poor dress quality and force excess material removal, reducing the life of the electrode and causing additional equipment downtime to change and maintain electrodes.
[006] Therefore, there exists a need for an apparatus and a method for dressing electrodes tips of a spot welding machine which obviates the aforementioned drawbacks.

OBJECTS
[007] The principal object of embodiments disclosed herein is to provide an apparatus for dressing electrode tips of a spot welding machine.
[008] Another object of the embodiments disclosed herein is to provide an apparatus for dressing electrode tips of a spot welding machine which is easy to manufacture.
[009] Yet another object of the embodiments disclosed herein is to provide an apparatus for dressing electrode tips of a spot welding machine which is inexpensive.
[0010] Still another object of the embodiments disclosed herein is to provide a method for dressing electrode tips of a spot welding machine.
[0011] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0012] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0013] FIG. 1 depicts a perspective view of an apparatus for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein;
[0014] FIG. 2 depicts a top view of an apparatus for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein;
[0015] FIG. 3 depicts a front view of an apparatus for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein; and
[0016] FIG. 4 depicts a flow chart of a method for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein.

DETAILED DESCRIPTION
[0017] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0018] The embodiments herein achieve an apparatus for dressing electrode tips of a spot welding machine. Further, the embodiments herein achieve a method for dressing electrode tips of a spot welding machine. Referring now to the drawings and more particularly to FIGS. 1 through FIG. 4, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0019] FIG. 1 depicts a perspective view of an apparatus for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein. In an embodiment, the apparatus 100 includes a base structure 101, an electrode tip dressing tool 103, a chip collector 105, an electrode tip 107, a chuck 109, a support member for chuck 111, a drill shank 113, a sliding unit 115, a hand wheel 117, a screw slider member 119, a frame 121, a holder 123, a guideway 125, and a chamber 127.
[0020] FIG. 2 and 3 depicts a top view and front view of the apparatus 100 respectively for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein. In an embodiment, the apparatus 100 includes the base structure 101. The base structure 101 is configured to support the other components of the apparatus 100. In an embodiment, the base 101 is made up of a rigid material.
[0021] In an embodiment, the apparatus 100 includes the frame 121. The frame 121 includes a plurality of vertical metal columns mounted on the base 101 at predetermined positions. The columns are interconnected by plurality of metal strips. The plurality of columns is affixed to the base 101 using plurality of bolts and nuts. However, it is also within the scope of the invention to provide any type attaching means between the columns and the base 101 for mounting the columns on the base 101 without otherwise deterring the intended function of mounting as can be deduced from this description and corresponding drawings.
[0022] In an embodiment, the apparatus 100 includes the guideway 125 defined in the base structure 101. The guideway 125 is configured to support the sliding unit 115 (not shown). The sliding unit 115 (not shown) is moved in the guideway 125 in at least one of forward and backward direction.
[0023] In an embodiment, the apparatus 100 includes the sliding unit 115 (not shown). The sliding unit 115 (not shown) is mounted above the base 101 and is configured to move within the guideway 125. In an embodiment, the sliding unit 115 (not shown) includes the screw slider member 119 which is coupled to the chuck 109. Further, the sliding unit 115 (not shown) includes the hand wheel 117 which is connected to the screw slider member 119. In an embodiment, the screw slider member 115 is moved in at least one of forward direction and backward direction by operating the hand wheel 117. In an embodiment, the sliding unit 115 (not shown) includes the support member 111 which is mounted on the base 101 and is configured to support the chuck 109.
[0024] In an embodiment, the chuck 109 is coupled to the screw slider member 119. In an embodiment, the chuck 109 is configured to grip the electrode tip 107 with aid of the drill shank 113. In an alternate embodiment, the chuck 109 is configured to hold different types of electrode tips 107. In an embodiment, the sliding unit 115 is configured to drive the electrode tip 107 against the electrode dressing tool 103.
[0025] In an embodiment, the apparatus 100 includes the electrode dressing tool 103. In an embodiment, the electrode dressing tool 103 includes a dressing head 103a having a cutting tool 103b for dressing the electrode tip 107. In an embodiment, the electrode dressing tool 103 is configured to be operated by a pneumatic means (not shown). In an embodiment, the pneumatic means (not shown) is a compressor. However, it is also within the scope of the invention to provide any type operating means to operate the cutting tool 103b defined in the electrode dressing tool 103 without otherwise deterring the intended function of dressing as can be deduced from this description and corresponding drawings.
[0026] In an embodiment, the pneumatic means (not shown) is adapted to rotatably operate a plurality of blades (not shown) defined in the cutting tool 103b to remove a predetermined depth of material from the electrode tip 107. The hand wheel 117 is operated to move the chuck 109 against the electrode dressing tool 103 to achieve a desired shape of the electrode tip 107. In an embodiment, the electrode tip 107 may be of any configuration and shape.
[0027] In an embodiment, the apparatus 100 includes the chip collector 105. The chip collector 105 is mounted on the base structure 101 to collect the chips formed while operating the electrode dressing tool 103.
[0028] In an embodiment, the apparatus 100 includes a chamber 127. In an embodiment, the chamber 127 is a pneumatic chamber (here after pneumatic chamber 127). In an embodiment, the pneumatic chamber 127 is supported in the frame 121. In an embodiment, the pneumatic chamber 127 includes plurality of air pipes (not shown) configured to supply air to the electrode dressing tool 103. In an embodiment, the pneumatic chamber 127 further includes at least one valve (not shown). In an embodiment, for example the at least one valve may be a direction control valve. In an embodiment, the apparatus 100 further includes a FRL unit (not shown) to strain any impurities in pneumatic air supply. In an embodiment, the apparatus 100 includes an electro pneumatic circuitry (not shown). In an embodiment, the electro pneumatic circuitry (not shown) includes a generator or fan (not shown), at least one transducer (not shown) and an indicating lamp (not shown). In an embodiment, the fan (not shown) is rotated by the air which drains or exhausts from the electrode dressing tool 103 during the operation. Further, the fan (not shown) operates the indicating lamp (not shown) by generating power (electricity). The fan (not shown) works on the principle of turbine to generate power. In an embodiment, the at least one transducer converts rotational power of the fan or generator into electricity.
[0029] In an embodiment, the indicating lamp (not shown) is operated without external power source. The indicating lamp (not shown) is configured to operate between on and off conditions. When the apparatus 100 is operated, the indicating lamp (not shown) is in on condition while the apparatus 100 is inoperative the indicating lamp (not shown) is in off condition.
[0030] In an embodiment, the electrode dressing tool 103 is located and supported by the holder 123. The holder 123 is attached to the frame 121 at a predetermined position. In an embodiment, the holder 123 is made of pyramid shape so as to accommodate the pneumatic chamber 127 along with the air pipes.
[0031] FIG. 4 depicts a flow chart of a method 200 for dressing electrode tips of a spot welding machine, according to an embodiment as disclosed herein. The method 200 for dressing electrode tips 107 of a spot welding machine includes steps of rotating a cutting tool 103b mounted with in an electrode dressing tool 103 (step 202). Further, the method includes moving a sliding unit 115 mounted on a base 101 towards the electrode dressing tool 103 (step 204). Furthermore, the method includes engaging an electrode tip 107 mounted on the sliding unit 115 against the rotating cutting tool 103b (step 206). In addition, the method includes dressing the electrode tip 107 by removing a predetermined depth of material from the electrode tip 107 (step 208).
[0032] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:STATEMENT OF CLAIMS
We claim,
1. An apparatus 100 for dressing electrode tip 107 of a spot welding machine, said apparatus 100 comprising:
a base structure 101;
a guideway 125 defined on the base structure 101;
a sliding unit 115 slidably supported in the guideway 125; and
an electrode dressing tool 103 mounted on the base structure 101 in communication with the sliding unit 115,
wherein
the electrode dressing tool 103 includes a dressing head 103a having a cutting tool 103b for dressing the electrode tip 107; and
the sliding unit 115 is configured to drive the electrode tip 107 against the cutting tool 103b;
the sliding unit 115 is configured to slide on the guide way 125 in at least one of forward and backward direction.
2. An apparatus 100 for dressing an electrode tip 107 of a spot welding machine, said apparatus 100 comprising:
a base structure 101;
a frame 121 mounted on the base structure 101;
a guideway 125 defined on the base structure 101;
a sliding unit 115 slidably supported in the guideway 125;
an electrode dressing tool 103 mounted on the base structure 101 in communication with the sliding unit 115; and
an electrode dressing tool holder 123 mounted on the frame 121,
wherein
the electrode dressing tool 103 includes a dressing head 103a having a cutting tool 103b for dressing the electrode tip 107; and
the electrode dressing tool holder 123 is configured to locate and support the electrode dressing tool 103;
the sliding unit 115 is configured to drive the electrode tip 107 against the cutting tool 103b;
the sliding unit 115 is configured to slide on the guide way 125 in at least one of forward and backward direction.
3. The apparatus 100 as claimed in claim 1, wherein the sliding unit 115 includes;
a screw slider member 119;
a chuck 109 coupled adjacent to the screw slider member 119;
a hand wheel 117 connected to the screw slider member 119; and
a support member 111 mounted on the base structure 101 to support the chuck 109.
4. The apparatus 100 as claimed in claim 2, wherein the sliding unit 115 includes a drill shank 113 coupled to the chuck 109.
5. The apparatus 100 as claimed in claim 2, wherein the chuck 109 is configured to grip the electrode tip 107 against the cutting tool 103b of the electrode dressing tool 103.
6. The apparatus 100 as claimed in claim 1, wherein the apparatus 100 includes a chip collector 105 mounted on the base 101 to collect the chips formed during operation.
7. The apparatus 100 as claimed in claim 1, wherein the cutting tool 103b includes a plurality of blade for dressing the electrode tip 107.
8. The apparatus 100 as claimed in claim 1, wherein the chuck 109 holding the electrode tip 107 is configured to move along a central axis of the cutting tool 103b.
9. The apparatus 100 as claimed in claim 1, wherein the apparatus 100 includes a chamber 127 supported by the frame 121 having a plurality of pipes and at least one valve.
10. A method 200 for dressing electrode tip 107 of a spot welding machine, said method comprising steps of:
rotating a cutting tool 103b mounted with in an electrode dressing tool 103;
moving a sliding unit 115 mounted on a base structure 101 towards the electrode dressing tool 103;
engaging an electrode tip 107 mounted on the sliding unit 115 against the rotating cutting tool 103b; and
dressing the electrode tip 107 by removing a predetermined depth of material from the electrode tip 107.
11. A method 201 for assembling an apparatus for dressing electrode tips 107 of a spot welding machine, said method comprising steps of:
providing a base structure 101;
mounting a frame 121 on the base structure 101;
defining a guideway 125 on the base structure 101;
providing a sliding unit 115 slidably supported in the guideway 125;
mounting an electrode dressing tool 103 in communication with the sliding unit 115;
providing an electrode dressing tool holder 123 in the frame 121; and
mounting a chip collector 105 on the base 101 adjacently below the electrode dressing tool 103,
wherein
the electrode dressing tool 103 includes a dressing head 103a in which a cutting tool 103b is mounted for dressing the electrode tip 107; and
the electrode dressing tool holder 123 is configured to locate and support the electrode dressing tool 103;
the sliding unit 115 is configured to drive the electrode tip 107 against the cutting tool 103b;
the sliding unit 115 is configured to slide on the guide way 125 in at least one of forward and backward direction.