Robotic shear stud welding system and method of use thereof

A ferrule gripper for a shear stud welding gun comprising:

• a first side with a first arm;
• and
• a second side with a second arm;
• the ferrule gripper is configured to open the first side from the second side by moving the first arm away from the second arm, and the ferrule gripper is configured to close the first side from the second side by moving the first arm toward the second arm;
• and
• wherein, when the ferrule gripper is closed a top chamber is created at a top portion of the ferrule gripper between the first side and the second side and a bottom chamber is created at a bottom portion of the ferrule gripper between the first side and the second side, where the top chamber is configured to fit around a single stud, and the bottom chamber is configured to grip a single ferrule and position the single ferrule at the bottom of the single stud.

An automated method of shooting a shear stud comprising:

• providing a robotic shear stud welding system comprising:
• a stud feeder configured to hold a plurality of studs and feed a single stud therefrom;
• a ferrule feeder configured to hold a plurality of ferrules and feed a single ferrule therefrom;
• at least one work zone;
• a robot with a controllable arm, the controllable arm is configured to accurately move between the stud feeder, the ferrule feeder, and each of the at least one work zones;
• and
• a welding gun attached to a distal end of the controllable arm, the welding gun including a ferrule gripper configured to grip the single ferrule and position the single ferrule at the bottom of the single stud;
• picking up the single stud from the stud feeder with the welding gun including using the ferrule gripper on the welding gun to pick up the single stud;
• picking up the single ferrule from the ferrule feeder with the welding gun including using the ferrule gripper on the welding gun to pick up the single stud;
• positioning the single ferrule at a bottom of the single stud with the welding gun including using the ferrule gripper on the welding gun to position the single ferrule at the bottom of the single stud;
• and
• shooting the single stud to a workpiece in one of the at least one work zones.

A robotic shear stud welding system comprising:

• a stud feeder configured to hold a plurality of studs and feed a single stud therefrom;
• a ferrule feeder configured to hold a plurality of ferrules and feed a single ferrule therefrom;
• at least two work zones, the at least two work zones including:
• a first work zone;
• and
• a second work zone;
• wherein, the robotic shear stud welding system is configured to operate exclusively in the first work zone while the second work zone is being prepared, or work exclusively in the second work zone while the first work zone is being prepared;
• a robot with a controllable arm, the controllable arm is configured to accurately move between the stud feeder, the ferrule feeder, and each of the at least two work zones;
• a welding gun attached to a distal end of the controllable arm, the welding gun attached to the distal end of the controllable arm of the robot is configured to pick up the single stud from the stud feeder, pick up the single ferrule from the ferrule feeder and position the single ferrule at a bottom of the single stud, and shoot the single stud to a workpiece in one of the at least two work zones;
• wherein:
• the first work zone including a first safety light curtain that is activated when the controllable arm is shooting studs in the first work zone and deactivated when the controllable arm is not shooting studs in the first work zone whereby the first work zone can be prepared;
• and
• the second work zone including a second safety light curtain that is activated when the controllable arm is shooting studs in the second work zone and deactivated when the controllable arm is not shooting studs in the second work zone whereby the second work zone can be prepared.

A robotic shear stud welding system comprising:

• a stud feeder configured to hold a plurality of studs and feed a single stud therefrom;
• a ferrule feeder configured to hold a plurality of ferrules and feed a single ferrule therefrom;
• at least one work zone;
• a robot with a controllable arm, the controllable arm is configured to accurately move between the stud feeder, the ferrule feeder, and each of the at least one work zones;
• a welding gun attached to a distal end of the controllable arm, the welding gun attached to the distal end of the controllable arm of the robot is configured to pick up the single stud from the stud feeder, pick up the single ferrule from the ferrule feeder and position the single ferrule at a bottom of the single stud, and shoot the single stud to a workpiece in one of the at least one work zones;
• wherein each of the at least one work zones including an electro magnet under the work zone, the electro magnet is configured to be energized to hold the workpiece down after the welding gun shoots the single stud on the workpiece and while the welding gun moves away from the single stud.

A robotic shear stud welding system comprising:

• a stud feeder configured to hold a plurality of studs and feed a single stud therefrom;
• a ferrule feeder configured to hold a plurality of ferrules and feed a single ferrule therefrom;
• at least one work zone;
• a robot with a controllable arm, the controllable arm is configured to accurately move between the stud feeder, the ferrule feeder, and each of the at least one work zones;
• a welding gun attached to a distal end of the controllable arm, the welding gun attached to the distal end of the controllable arm of the robot is configured to pick up the single stud from the stud feeder, pick up the single ferrule from the ferrule feeder and position the single ferrule at a bottom of the single stud, and shoot the single stud to a workpiece in one of the at least one work zones;
• and
• a control panel configured to control the robotic shear stud welding system including controlling the controllable arm of the robot, the welding gun, the stud feeder, the ferrule feeder, and the at least one work zone, wherein the control panel including a user input device with a touch screen configured to allow a user to configure the robotic shear stud welding system.