Resistance spot rivet welding systems and methods of use thereof

1. A resistance spot rivet welding system comprising:

(i) a rivet dispensing system comprising:

a first rivet receiving member defining a first channel therein, the first rivet receiving member comprising

an inlet communicating with the first channel and configured to receive rivets,

an outlet communicating with the first channel and configured to dispense rivets,

wherein the first channel extends between the inlet and the outlet and is configured to transport rivets from the inlet to the outlet;

a seat member communicating with the outlet and configured to selectively engage with a rivet holder of a resistance spot rivet welding apparatus and introduce a single rivet to the rivet holder at one time, wherein the seat member comprises a first jaw, a second jaw, and a block structure to receive a rivet from the second port and maintain the rivet in a preselected position and orientation; and

an actuation member configured to move a rivet located within the seat member to a secondary position located above the seat member; and

(ii) the rivet holder comprising a collet assembly, the collet assembly comprising an actuator and a collet connected to the actuator, the collet assembly being adapted to be installed on an external electrode holder, the collet being moveable by the actuator from an advanced position, in which the collet is adapted to grip a rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable an electrode attached to the electrode holder to engage the rivet.

2. A resistance spot rivet welding method comprising:

(i) reloading rivets into a rivet dispensing system used with a resistance spot rivet welding system, the reloading comprising:

receiving and storing a plurality of rivets in a channel of a rivet receiving member of a rivet dispenser reloading system, wherein the rivet dispenser reloading system comprises a gate associated with the channel, wherein the gate is selectively positionable between a first configuration inhibiting movement of rivets from the channel, and a second configuration enabling movement of rivets from the channel;

aligning a rivet dispensing system of a resistance spot rivet welding system with the rivet receiving member utilizing an alignment member in communication with the resistance spot rivet welding apparatus; and

introducing the plurality of rivets stored in the channel into the rivet dispensing system via the gate;

(ii) dispensing a rivet from the rivet dispensing system onto a rivet holder of a resistance spot rivet welding apparatus, the dispensing comprising:

receiving the rivet and storing the rivet on a seat member of the rivet dispensing system, wherein the seat member comprises a first jaw, a second jaw, and a block structure to receive a rivet from the second port and maintain the rivet in a preselected position and orientation;

moving the rivet dispensing system utilizing an actuation member along a path to align the seat member with the rivet holder;

introducing the rivet stored on the seat member to the rivet holder; and

receiving the rivet, by the rivet holder, from the rivet dispensing system.

3. A resistance spot rivet welding system comprising:

(i) a rivet dispensing system comprising:

a first rivet receiving member defining a first channel therein, the first rivet receiving member comprising

an inlet communicating with the first channel and configured to receive rivets,

an outlet communicating with the first channel and configured to dispense rivets,

wherein the first channel extends between the inlet and the outlet and is configured to transport rivets from the inlet to the outlet; and

a seat member communicating with the outlet and configured to selectively engage with a rivet holder of a resistance spot rivet welding apparatus and introduce a single rivet to the rivet holder at one time;

(ii) the rivet holder comprising a collet assembly, the collet assembly comprising an actuator and a collet connected to the actuator, the collet assembly being adapted to be installed on an external electrode holder, the collet being moveable by the actuator from an advanced position, in which the collet is adapted to grip a rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable an electrode attached to the electrode holder to engage the rivet; and

(iii) a rivet dispenser reloading system comprising:

a second rivet receiving member defining a second channel therein, the second rivet receiving member comprising

a first port communicating with the second channel and configured to receive rivets, and

a second port communicating with the second channel and configured to selectively engage with the rivet dispensing system and introduce rivets to the rivet dispensing system,

wherein the second channel extends between the first port and the second port and is configured to transport rivets from the first port to the second port; and

a first gate in communication with the second port, wherein the first gate is selectively positionable between a first configuration inhibiting movement of rivets through the second port, and a second configuration enabling movement of rivets through the second port.

4. The resistance spot rivet welding system of claim 3 , further comprising a second gate in communication with the second channel of the rivet dispenser reloading system, the second gate configured to enable movement of a single rivet at one time through the second port of the second rivet receiving member of the rivet dispenser reloading system, while inhibiting movement of additional rivets through the second port of the second rivet receiving member of the rivet dispenser reloading system.

5. The resistance spot rivet welding system of claim 4 , further comprising a third gate in communication with the first port of the second rivet receiving member of the rivet dispenser reloading system, wherein the third gate is selectively positionable between a first configuration inhibiting movement of rivets through the first port of the second rivet receiving member of the rivet dispenser reloading system, and a second configuration enabling movement of rivets through the first port of the second rivet receiving member of the rivet dispenser reloading system.

6. The resistance spot rivet welding system of claim 3 , further comprising

a fastener feeder configured to introduce fasteners in a preselected orientation to the first port of the second rivet receiving member of the rivet dispenser reloading system, wherein the fastener feeder comprises at least one of a vibratory bowl and a magnetic collator.

7. The resistance spot rivet welding system of claim 3 , further comprising an electrode dressing component associated with the second port of the second rivet receiving member of the rivet dispenser reloading system, the electrode dressing component configured to dress the electrode attached to the electrode holder as the rivet dispensing system receives rivets from the second port of the second rivet receiving member of the rivet dispenser reloading system.

8. The resistance spot rivet welding system of claim 3 , further comprising a frame configured to retain the rivet dispenser reloading system, the rivet dispensing system, the rivet holder, or a combination thereof, in a plurality of preselected orientations.

9. The resistance spot rivet welding system of claim 3 , wherein the rivet dispenser reloading system further comprises an alignment member in communication with the second rivet receiving member of the rivet dispenser reloading system, the alignment member configured to facilitate alignment between the second rivet receiving member of the rivet dispenser reloading system and the first rivet receiving member of the rivet dispensing system.

10. The resistance spot rivet welding system of claim 3 , wherein the rivet dispenser reloading system further comprises a contact block in communication with the second port of the second rivet receiving member of the rivet dispenser reloading system and configured to engage the rivet dispensing system.

11. The resistance spot rivet welding system of claim 3 , wherein the rivet dispenser reloading system further comprises a sensor configured to detect an orientation of rivets within the second channel defined by the second rivet receiving member of the rivet dispenser reloading system.

12. The resistance spot rivet welding system of claim 3 , wherein the rivet dispenser reloading system further comprises a sensor configured to detect the quantity of rivets within the second channel defined by the second rivet receiving member of the rivet dispenser reloading system.

13. The resistance spot rivet welding system of claim 1 , wherein the rivet dispensing member further comprises a tensioner configured to urge the rivets towards the seat member of the rivet dispensing system.

14. The resistance spot rivet welding system of claim 1 , wherein the rivet dispensing member further comprises a drive unit comprising a first linkage and a second linkage, the drive unit configured to move the first rivet receiving member along a path between a first position and a second position.

15. The resistance spot rivet welding system of claim 1 , wherein the collet of the rivet holder comprises an elongated shank portion and a plurality of collet fingers extending from the shank portion, the plurality of collet fingers being sized and shaped to grip a rivet when the collet is in its advanced position, each of the plurality of collet fingers comprising a gripping portion, wherein each gripping portion comprises a tapered member that is tapered inwardly relative to a longitudinal axis of the collet.

16. A resistance spot rivet welding system comprising:

(i) a rivet dispensing system comprising:

a first rivet receiving member defining a first channel therein, the first rivet receiving member comprising

an inlet communicating with the first channel and configured to receive rivets,

an outlet communicating with the first channel and configured to dispense rivets,

wherein the first channel extends between the inlet and the outlet and is configured to transport rivets from the inlet to the outlet; and

a seat member communicating with the outlet and configured to selectively engage with a rivet holder of a resistance spot rivet welding apparatus and introduce a single rivet to the rivet holder at one time; and

(ii) the rivet holder comprising a collet assembly, the collet assembly comprising an actuator and a collet connected to the actuator, the collet assembly being adapted to be installed on an external electrode holder, the collet being moveable by the actuator from an advanced position, in which the collet is adapted to grip a rivet, and a retracted position, in which at least a portion of the collet is retracted into the actuator to enable an electrode attached to the electrode holder to engage the rivet;

wherein the actuator of the rivet holder comprises a housing comprising an upper end, a lower end opposite the upper end, and a central passage extending from the upper end to the lower end;

wherein the collet is positioned and can slide within the central passage of the housing of the actuator;

wherein the actuator of the rivet holder comprises a sleeve member comprising an inner sleeve positioned within the central passage of the housing of the actuator;

wherein the collet comprises an internal passage; and

wherein the inner sleeve of the sleeve member of the actuator is positioned within the internal passage of the collet.

17. The resistance spot rivet welding system of claim 16 , wherein the inner sleeve includes a free end comprising a beveled surface and is positioned within the central passage of the housing proximate to the lower end of the housing, and wherein when the collet moves from the advanced position to the retracted position, the tapered members of the collet engage the beveled surface of the inner sleeve.

18. The method of claim 2 , wherein a rivet of the plurality of rivets is received in the channel of the rivet receiving member of the rivet dispenser reloading system concurrently with the resistance spot rivet welding apparatus system utilizing a rivet to fasten a structure.

19. The method of claim 2 , further comprising utilizing the resistance spot rivet welding apparatus to attach the rivet received in the rivet holder to a structure.