Projection welding electrode holder with adjustable instantaneous extension stroke

A projection welding electrode holder, comprising:

• a holder body, the holder body configured for attachment to a welding machine, the holder body having an opening at one end and defining an internal cavity within the opening, the cavity being free of flowing coolant;
• a holder barrel, the holder barrel having a holder head configured to carry a welding electrode, a holder axle extending opposite the holder head, and a holder slider disposed between the holder head and the holder axle, the holder axle and the holder slider residing within the internal cavity and the holder head extending from the holder body;
• the holder head, the holder axle, and the holder slider being integral and electrically conductive;
• the holder barrel being movable relative to the holder body and relative to the welding machine between a first position and a second position, in which the holder head extends from the holder body a first distance when the holder barrel is in the first position and the holder head extends from the holder body a second distance when the holder barrel is in the second position, the first distance being greater than the second distance;
• and
• a first Belleville washer, the first Belleville washer being annular and defining a central channel, the first Belleville washer residing within the cavity and opposite the slider from the holder head with the holder axle disposed within the central channel, the first Belleville washer biasing the holder barrel toward the first position, the first Belleville washer being compressed by movement of the holder barrel from the first position to the second position.

A projection welding electrode holder, comprising:

• a holder body, the holder body:
• configured for static attachment to a welding machine;
• being electrically conductive;
• having a first end and an opposed second end;
• and
• defining a cylindrical cavity therein with a first diameter, the cavity open at the first end of the holder body and walled at the second end and devoid of flowing coolant;
• a holder body cover, the cover removably attached to the first end of the holder body and having an opening therethrough;
• a holder barrel, the holder barrel having a holder head configured to carry a welding electrode, a holder axle extending opposite the holder head, and a holder slider disposed between the holder head and the holder axle, the holder axle and the holder slider residing within the internal cavity and the holder head extending from the holder body through the opening of the cover, the holder slider having a second diameter sized to complement the first diameter;
• the holder head, the holder axle, and the holder slider being integral and electrically conductive;
• the holder barrel being movable relative to the holder body and relative to the welding machine between a first position and an opposite second position, in which the holder head extends from the holder body a first distance when the holder barrel is at the first position and the holder head extends from the holder body a second distance when the holder barrel is at the second position, the first distance being greater than the second distance;
• the holder head including a coolant channel, the coolant channel isolated from the holder body cavity;
• and
• a first Belleville washer, the first Belleville washer being an annular open ring, the first Belleville washer residing within the cavity and opposite the slider from the holder head with the holder axle disposed within the open ring, the first Belleville washer biasing the holder barrel toward the first position, the first Belleville washer being compressed by movement of the holder barrel from the first position to the second position.