System, method and apparatus for stud welding

A stud welding assembly for moving over the surface of a base material and to sequentially position and weld a plurality of welding studs;

• the stud welding assembly comprising:
• a welding assembly main body;
• an upper ball bearing carriage track;
• a lower ball bearing carriage track;
• wherein the upper and lower ball bearing carriage tracks are attached to a front surface of the welding assembly main body;
• a left stud gun assembly;
• wherein the left study gun assembly comprises:
• a left vertical positioning assembly;
• a left stud welding gun;
• and
• a left stud welding gun leg;
• a right stud gun assembly;
• wherein the right stud gun assembly comprises:
• a right vertical positioning assembly;
• a right stud welding gun;
• and
• a right stud welding gun leg;
• wherein the left stud gun assembly is movably attached to the upper ball bearing carriage track and the lower ball bearing carriage track;
• wherein the right stud gun assembly is movably attached to the upper ball bearing carriage track and the lower ball bearing carriage track;
• wherein the upper and lower ball bearing carriage tracks allow the right and left stud welding guns to horizontally translate across the front face of the stud welding assembly;
• a system controller;
• wherein the system controller is configured to direct the movement of the right and left stud welding gun assemblies to one or more targeted Y-axis values;
• a plurality of side rollers;
• a plurality of drive rollers;
• wherein the system controller is configured to control the rotational movement of the plurality of side rollers and the plurality of drive rollers;
• wherein the plurality of drive rollers and the plurality of side rollers are configured to frictionally receive and pull the base material to propel the stud welding assembly across the surface of the base material;
• wherein the system controller is configured to control the side rollers and the drive rollers to position the stud welding assembly and the stud welding guns to a targeted X-axis value;
• and
• a plurality of guide plates;
• wherein the plurality of guide plates comprise at least a left guide plate and a right guide plate;
• wherein the plurality of guide plates comprise smooth upper surfaces to receive the base material;
• wherein the left guide plate forms a left docking slot;
• wherein the left docking slot is adjustably sized to receive the base material with the base material in contact between the left docking slot and at least one drive roller;
• wherein the left and right vertical positioning assemblies are configured to adjust the vertical distance between the right and left stud welding guns and the received base material as the base material moves within the right docking slot and left docking slot;
• wherein the system controller is configured to independently adjust the positions of the right and left stud welding guns along the Z-axis relative to the base material to a targeted Z-axis value.