Terminal box for gas tungsten arc welding training system

Abstract

A junction box for a gas tungsten arc welding (GTAW) training system is described. In some examples, the junction box of the GTAW training system coordinates the delivery of welding-type power to a GTAW torch during training. In some examples, a remote control (e.g., a foot pedal) can be activated to varying degrees to command different levels of welding-type power to be delivered from a welding-type power supply to the GTAW torch. In some examples, the junction box can selectively enable or disable communication between the remote control and the welding-type power supply during training. In some examples, the selective enabling / disabling can be based on whether the GTAW training system is in live arc mode or simulation mode.

Description

Technical Field

[0001] The present disclosure relates generally to gas tungsten arc welding (GTAW) training systems, and more particularly to terminal boxes for GTAW training systems. Background Art

[0002] The welding industry is short of experienced and skilled operators. In addition, even experienced welders have difficulty maintaining important welding techniques (e.g., torch working angle, torch travel angle, contact tip to workpiece distance, travel speed, alignment, etc.) throughout the welding process. Welding training systems allow both experienced and inexperienced welding operators to practice to produce high-quality welds.

[0003] The limitations and disadvantages of conventional and traditional approaches will become apparent to those skilled in the art through comparison of such systems with the present disclosure as set forth in the remainder of this application with reference to the accompanying drawings. Summary of the invention

[0004] The present disclosure is directed to a terminal block for a GTAW training system substantially as shown in and / or described in conjunction with at least one of the accompanying drawings and as more fully set forth in the claims.

[0005] These and other advantages, aspects and novel features of the present disclosure, as well as details of illustrated examples thereof, will be more fully understood from the following description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 An example of a gas tungsten arc welding (GTAW) training system according to aspects of the present disclosure is shown.

[0007] Figure 2 It is to further illustrate the various aspects of the present disclosure Figure 1 Block diagram of example components of a GTAW training system.

[0008] Figure 3 It is a diagram illustrating various aspects of the present disclosure that can be used with Figure 1 A flow chart of an example GTAW training procedure for use with the GTAW training system.

[0009] Figure 4 It is shown that according to various aspects of the present disclosure, Figure 1 An example GTAW welding torch used in an example GTAW training system.

[0010] FIG. 5a shows a schematic diagram of a method for performing a multi-layered structure according to various aspects of the present disclosure. Figure 1 Example electrodes and electrode accessories used in the GTAW training system.

[0011] FIG. 5b shows a schematic diagram of a method for performing a multi-layered structure according to various aspects of the present disclosure. Figure 1 Another example welding electrode and welding electrode accessories used in an example GTAW training system.

[0012] FIG. 5c shows a schematic diagram of a method for performing a multi-layered structure according to various aspects of the present disclosure. Figure 1 Another example welding electrode and welding electrode accessories used in an example GTAW training system.

[0013] Figure 6 It is a diagram showing various aspects of the present disclosure. Figure 1 Example components of the GTAW training system's junction box with Figure 1 A block diagram of the interrelationship of the other components of the GTAW training system.

[0014] Figure 7 It is a diagram illustrating various aspects of the present disclosure that can be used with Figure 6 A flow chart of an example box control method for use with a junction box.

[0015] The drawings are not necessarily drawn to scale. Where appropriate, the same or similar reference numbers are used to represent similar or identical elements in the drawings. For example, reference numbers using letters (e.g., sensor 104a, sensor 104b) represent instances of the same reference number (e.g., sensor 104) without the letter. DETAILED DESCRIPTION

[0016] Some examples of the present disclosure relate to a junction box of a gas tungsten arc welding (GTAW) training system, the junction box comprising: a remote control input device, the remote control input device being configured to receive a remote control signal from a remote control; a remote control output device, the remote control output device being configured to provide the remote control signal to a welding-type power supply; a switch, the switch being configured to selectively couple the remote control input device to the remote control output device; and a control circuit system, the control circuit system being configured to: provide a training signal representing the remote control signal to a welding training controller; in a live arc mode, control the switch to selectively couple the remote control input device to the remote control output device so that the remote control signal can be transmitted to the welding-type power supply; and in a simulation mode, control the switch to selectively decouple the remote control input device from the remote control output device to prevent the remote control signal from being transmitted to the welding-type power supply.

[0017] In some examples, the remote control input device includes an input port or an input communication circuit system, and the remote control output device includes an output port or an output communication circuit system. In some examples, the remote control includes a foot pedal. In some examples, the switch includes a relay. In some examples, the junction box further includes: a power input port, the power input port is configured to receive welding power from the welding power supply; and a power output port, the power output port is configured to provide the welding power to the GTAW welding torch, the power input port and the power output port are electrically connected via a power line. In some examples, the junction box further includes: a sensor in electrical communication with the control circuit system and the power line, the sensor being configured to detect a current or voltage on the power line. In some examples, the control circuit system is further configured to provide a signal representing the current or voltage to the welding training controller.

[0018] In some examples, the junction box further includes: a torch connection device configured to be electrically connected to a GTAW welding torch, and the control circuit system is configured to provide one or more torch output signals to the GTAW welding torch via the torch connection device. In some examples, the control circuit system is further configured to receive one or more torch input signals from the GTAW welding torch via the torch connection device, and the one or more torch input signals represent the selection of the live arc mode or the simulation mode. In some examples, the junction box further includes: a training connection device configured to be electrically connected to the welding training controller, and the control circuit system is configured to provide the training output signal to the welding training controller via the training connection device, wherein the control circuit system is further configured to receive one or more training input signals from the welding training controller via the training connection device, and the one or more training input signals represent the live arc mode or the simulation mode.

[0019] Some examples of the present disclosure relate to a method for operating a junction box of a GTAW training system, the method comprising: receiving a remote control signal from a remote control of a GTAW welding torch via a remote control input device of the junction box; providing a training signal representing the remote control signal to a welding training controller via a training connection device of the junction box; in a live arc mode, providing the remote control signal to the welding-type power supply; and in a simulation mode, preventing the remote control signal from being provided to the welding-type power supply.

[0020] In some examples, the method further includes: receiving a mode signal from the welding training controller via the training connection device, the mode signal indicating a live arc mode or a simulated mode. In some examples, providing the remote control signal to the welding-type power supply includes: controlling a switch of the junction box to selectively couple the remote control input device to a remote control output device of the junction box, the remote control output device being configured to couple to the welding-type power supply. In some examples, preventing the remote control signal from being provided to the welding-type power supply includes: controlling a switch to selectively decouple the remote control input device from a remote control output device of the junction box, the remote control output device being configured to couple to the welding-type power supply. In some examples, the remote control includes a foot pedal.

[0021] In some examples, the method further includes: receiving one or more torch input signals from the GTAW welding torch via the torch connection device of the junction box, and sending the one or more torch input signals to the welding training controller via the training connection device, the one or more torch input signals representing the selection of the live arc mode or the simulation mode. In some examples, the method further includes: controlling one or more torch output indicators of the GTAW welding torch via the torch connection device of the junction box. In some examples, the method further includes: controlling one or more torch marks of the GTAW welding torch via the torch connection device of the junction box. In some examples, the method further includes: measuring the current or voltage on the power line of the junction box via a sensor, the power line being electrically connected to a power port configured to be electrically connected to the welding-type power supply. In some examples, the method further includes: sending one or more signals representing the current or voltage to the training controller via the training connection device.

[0022] Some examples of the present disclosure relate to gas tungsten arc welding (GTAW) training systems. Although there are existing welding training systems for gas metal arc welding (GMAW) systems and shielded metal arc welding (SMAW) systems, the GTAW system has its own special difficulties in welding training. For example, in GMAW and / or SMAW systems, manipulating the welding "torch" or "welding gun" also manipulates the filler material. Therefore, changing the position and / or orientation of the "torch" or "welding gun" also changes the position and / or orientation of the filler material. In the GTAW system, the filler material is separated from the torch or welding gun (and / or manipulated separately). Therefore, changing the position and / or orientation of the "torch" or "welding gun" does not change the position and / or orientation of the filler material. In addition, the filler material in the GMAW and / or SMAW system also acts as an electrode, while the filler material in the GTAW system is completely separated from the electrode. In addition, in the GMAW and / or SMAW system, the electrical power used to generate the arc is usually continuous (e.g., in the case of SMAW) or activated via a trigger on the torch or welding gun (e.g., in the case of GMAW). In a GTAW system, the electrical power used to generate the arc may be activated (and / or incrementally controlled) using a remote control (eg, a foot pedal) that is separate from both the welding torch / gun and the filler material.

[0023] The present disclosure contemplates a welding training system dedicated to gas tungsten arc welding. In some examples, the GTAW training system of the present disclosure includes a GTAW welding torch and an electrode attachment having one or more markings to facilitate detection and / or tracking of the position and / or orientation of the GTAW welding torch and the electrode. One or more sensors of the GTAW training system are configured to capture data related to the markings of the GTAW welding torch and / or the electrode attachment. A training controller of the GTAW training system can use the markings and / or sensor data to track and / or determine the position, orientation and / or movement of the GTAW welding torch and / or the electrode. The position, orientation and / or movement can be analyzed in conjunction with the welding parameter data to provide training feedback.

[0024] In some examples, a junction box of the GTAW training system coordinates the delivery of welding-type power to a GTAW welding torch during training. In some examples, a remote control (e.g., a foot pedal) can be activated to varying degrees to command different levels of welding-type power to be supplied from a welding-type power supply. In some examples, the junction box can selectively enable or disable communication between the remote control and the welding-type power supply during training. In some examples, the selective enabling / disabling can be based on whether the GTAW training system is in live arc mode or simulation mode.

[0025] Figure 1An example of a GTAW training system 100 is shown. In some examples, part or all of the GTAW training system 100 may include a virtual reality, augmented reality, and / or mixed reality GTAW training system 100. As shown, the GTAW training system 100 includes a welding station 102, a number of sensors 104, a welding-type power supply 108, a junction box 600, a remote control 140, a GTAW welding torch 400, a welding electrode 112, and a welding electrode accessory 500.

[0026] Figure 5A An example electrode attachment 500a of the GTAW training system 100 is shown. Figure 5A In the example of FIG. 5 , the electrode attachment 500a includes a rectangular parallelepiped 502. As shown, the rectangular parallelepiped 508 has several flat interconnected faces. Figure 5A In the example of the welding rod 112, the welding rod accessory 500a is shown as a rectangular parallelepiped 502, but in some examples, the welding rod accessory 500a can be an object of a different shape with several flat interconnected faces. As shown, the rectangular parallelepiped 502 has an orifice 504 on one face. As shown, the orifice 504 leads to a channel 506, which extends partially through the rectangular parallelepiped 502 and terminates at or before the end 508 of the rectangular parallelepiped 502. In some examples, the orifice 504 and / or the channel 506 are sized to comfortably and / or tightly receive a portion of the welding rod 112 so as to frictionally hold the welding rod accessory 500a on the welding rod 112.

[0027] exist Figure 5A In the example of FIG. 5 , the cuboid 502 includes several attachment markers 513. As shown, the attachment markers 513 are passive markers, such as reflectors. In some examples, the attachment markers 513 can also be active markers, such as light emitting diodes (LEDs). Figure 5AIn the example of FIG. 1 , two accessory marks 513 are provided on each face of the cuboid 502. In some examples, more or fewer accessory marks 513 may be provided on each face. In some examples, the distance between two accessory marks 513 (e.g., 513a and 513b) on each same face of the cuboid 502 may be unique compared to the distance between any two accessory marks 513 (e.g., 513a and 513c / 513d, or 513b and 513c / 513d) on adjacent faces of the cuboid 502. In this way, the GTAW training system 100 is able to determine which accessory marks 513 are on the same face of the cuboid 502 by comparing the distances between the accessory marks 513, thereby determining which pair (and / or which group) of accessory marks 513 define an axis parallel to the axis of the electrode 112. Once the parallel axis is known, the GTAW training system 100 can project the axis toward the GTAW torch 400 (and / or the tip of the tungsten electrode 414) and / or the workpiece 110 to determine the orientation and / or angle 112 at which the electrode may interact with the arc, the GTAW torch 400 (and / or the tip of the tungsten electrode 414), and / or the workpiece 110. Additionally, in some examples, the accessory markers 513 can be arranged in a manner to form a rigid body that the GTAW training system 100 can use to determine both relative position and orientation.

[0028] Figure 5B Another example welding electrode attachment 500b is shown. Figure 5B In the example of , the electrode attachment 500 includes two spheres 520 connected together via a hollow tube 522. As shown, the sphere 520a includes an opening 524. In some examples, the opening includes an inlet that communicates with a through hole in the sphere 520a, which is coaxial with the hollow tube 522, whereby the welding electrode 112 can be inserted into the hollow tube 522 through the opening 524 (and / or the sphere 520a). In some examples, the passage extending through the hollow tube 522 can terminate at the sphere 520b. In some examples, the passage can partially extend through the sphere 520b. In some examples, the orifice 524, the through hole extending through the sphere 520a (and / or the sphere 520b), and / or the size of the hollow tube 522 can be set to comfortably and / or tightly receive a portion of the welding electrode 112 so as to frictionally hold the welding electrode attachment 500b on the welding electrode 112. In some examples, each sphere 520 may include active or passive markers to facilitate detection (and / or axis projection) by the GTAW training system 100 .

[0029] Figure 5C Another example welding electrode attachment 500c is shown. Figure 5CIn the example of , the electrode attachment 500 includes two spheres 530 connected together via a solid rod 532 rather than a hollow tube. Instead, the hollow tube 534 is attached to the sphere 530a via an extension rod 536 extending from the sphere 530a. Figure 5C In the example of the embodiment of the present invention, the extension rod 536 is coaxial with the solid rod 532. In some examples, the solid rod 532 can extend through the sphere 530a, and the extension rod 536 can be a portion of the solid rod 532. As shown, the hollow tube 534 includes an opening 538 configured to receive the welding electrode 112. In some examples, the opening 538 and / or the hollow tube 534 can be sized to comfortably and / or snugly receive a portion of the welding electrode 112 so as to frictionally retain the welding electrode attachment 500c on the welding electrode 112. In some examples, each sphere 530 can be an active or passive marker to facilitate detection (and / or axis projection) by the GTAW training system 100.

[0030] exist Figure 1 In the example of FIG. 1 , an operator 116 wearing a welding headgear 106 having a mask 124 is shown manipulating a GTAW welding torch 400 and a welding rod 112 near a welding station 102 and a number of workpieces 110. As shown, the GTAW welding torch 400 is coupled to a junction box 600 via a welding cable. Figure 1 One GTAW welding torch 400 is shown in FIG. 1 , but in some examples, the GTAW training system 100 may include multiple GTAW welding torches 400. Figure 1 In the example, further, a sensing device 105 (e.g., an accelerometer) is integrated with the GTAW welding torch 400 to facilitate tracking the position, orientation, and / or movement of the GTAW welding torch 400.

[0031] Figure 4 Shows Figure 1 An enlarged view of an example GTAW welding torch 400 of the example GTAW training system 100. Figure 4 In the example of , the GTAW welding torch 400 includes a head 402 connected to a handle 406 via a neck 404. In some examples, the neck 404 can be rigid. In some examples, the neck 404 can be flexible to allow the head 402 to be reoriented and / or adjusted relative to the handle 406. As shown, the welding torch head 402 includes a body 408 attached to a nozzle 410, and a back cap 412 extending from the rear of the body 408. In some examples, the body 408 can be separated from the GTAW welding torch 400 so that the body 408 can be removed from different welding torches and / or attached to different welding torches.

[0032] exist Figure 4In the example of the embodiment of the present invention, the tungsten electrode 414 extends from the nozzle 410. In the nozzle 410, the electrode 414 can be held by a collet (not shown). In operation, the handle 406 can be connected to a cable that delivers welding-type power and / or gas to the GTAW welding torch 400. In the GTAW welding torch 400, welding-type power can be delivered to the tungsten electrode 414 to form an arc. Similarly, gas can be delivered to the welding torch nozzle 410 to be distributed near the arc. In some examples, the GTAW welding torch 400 can be configured as a simulation welding torch that cannot perform actual welding and does not require a tungsten electrode 414.

[0033] exist Figure 4 In the example of FIG. 4 , the torch head 402 includes a number of torch markers 413 attached to the torch body 408. By attaching the torch markers 413 to the body 408 (and / or the head 402), the torch markers 413 and the tungsten electrode 414 can maintain a fixed spatial relationship even if the position / orientation of the head 402 is reoriented and / or adjusted relative to the handle 406 via the neck 404. In some examples, the GTAW training system 100 can use the fixed spatial relationship to predict, estimate, and / or approximate the position and / or orientation of the tungsten electrode 414 based on the detected position and / or orientation of the torch markers 413.

[0034] In some examples, the fixed arrangement of the torch markings 413 formed on the solid surface of the body 408 can define a rigid body. In some examples, the rigid body defined by the torch markings 413 can allow the GTAW training system 100 to determine the position and orientation of the GTAW torch 400. Figure 4 In the example of the embodiment, all torch markers 413 are in one group, but in some examples, the torch markers 413 can be arranged in multiple groups, wherein each group has at least three torch markers 413 (so as to define a rigid body). In some examples, multiple groups of torch markers 413 can facilitate consistent and / or robust tracking at a variety of angles and orientations. In some examples, the torch markers 413 can include or be retained in a hole, cavity, receptacle, and / or other structure in the body 408.

[0035] In some examples, one or more torch markers 413 may include passive markers, such as reflectors, pattern markers, and / or other non-powered markers. In some examples, one or more torch markers 413 may include active markers, such as luminous markers (e.g., infrared light emitting diodes (LEDs)). In some examples, active markers on the GTAW torch 400 can be better used for live welding because (compared to passive markers) less camera exposure is required to capture active markers. Shorter exposure times can result in a lower risk of interference with other light sources (e.g., welding arcs, sparks, spatter, etc.) near the GTAW torch 400. In some examples where the torch marker 413 is an active marker, the torch marker 413 can receive power via a cable attached to the handle 406 (e.g., from the junction box 600) and / or from an internal power source of the GTAW torch 400 (e.g., a battery in the handle 406 or the head 402). In some examples where the torch markings 413 are active markings, individual torch markings 413 (and / or groups of torch markings 413) can be selectively activated and / or deactivated in response to one or more control signals (e.g., from the junction box 600).

[0036] exist Figure 4 In the example of , the GTAW welding torch 400 includes a welding torch input 416, a welding torch output 418, and a feedback mechanism 420. Figure 4 In the example of , two torch inputs 416 and two torch outputs 418 are shown, but in some examples, the GTAW welding torch 400 may include more or fewer torch inputs 416 and / or torch outputs 418. In some examples, the torch input 416 may include a button, switch, dial, knob, microphone, and / or other appropriate input mechanism. In some examples, the torch output 418 may include a visual output (e.g., a display, a light, etc.) and / or an audio output (e.g., a speaker). In some examples, the feedback mechanism 420 may include a tactile feedback mechanism and / or a vibration mechanism.

[0037] As shown, the GTAW welding torch 400 further includes an internal torch circuit system 422 in electrical communication with the torch input 416 and / or the torch output 418. In some examples, the internal torch circuit system 422 can be configured to drive, control, and / or otherwise facilitate the operation of the torch input 416, the torch output 418, the torch indicia 413, and / or the feedback mechanism 420. In some examples, the GTAW welding torch 400 can include an internal power source to power the torch input 416, the torch output 418, the feedback mechanism 420, the torch indicia 413, and / or the torch circuit system 422. In some examples, the GTAW welding torch 400 can receive power through a cable connection (e.g., with the junction box 600) to power the torch input 416, the torch output 418, the feedback mechanism 420, the torch indicia 413, and / or the torch circuit system 422.

[0038] In some examples, the operator 116 can provide input to the GTAW training system 100 using the torch inputs 416, the torch outputs 418, and / or the feedback mechanism 420, and receive output and / or feedback from the GTAW training system. For example, during setup / calibration of the GTAW training system 100, the operator 116 can use one or more torch inputs 416 to select a live arc mode or a simulated mode. In such an example, the GTAW torch 400 can send one or more signals indicating such a selection to the junction box 600 and / or the training controller 200. As another example, the junction box 600 and / or the training controller 200 can send one or more signals indicating a mode (e.g., live arc or simulated) to the GTAW torch 400, and one or more torch outputs 418 can provide the appropriate mode indication to the operator 116. As another example, the terminal box 600 (and / or the welding torch circuit system 422) can control the feedback mechanism 420 to provide feedback (e.g., vibration) in response to some training results (e.g., high score, low score, travel speed too fast / slow, arc length too large / small, angle too large / small, mode selection successful, etc.).

[0039] exist Figure 1In the example of , the remote controller 140 is also coupled to the junction box 600 via a cable. As shown, the remote controller 140 is a movable foot pedal. In some examples, the remote controller 140 can be a switch, a trigger, a button, a joystick, a dial and / or other suitable control mechanism (e.g., mounted to the GTAW welding torch 400). In some examples, the remote controller 140 is configured to detect the activation (e.g., stepping on) and / or movement of the movable pedal, and output one or more control signals based on the degree of activation and / or the amount of movement (and / or its indication). In some examples, the remote controller 140 can transmit one or more control signals to the junction box and / or the welding power supply 108. In some examples, the operator 116 can press and / or move the movable pedal to different degrees to command different target levels of welding power to be delivered to the GTAW welding torch 400, and the welding power supply 108 can interpret and / or respond to the representative signal from the remote controller 140 accordingly. In some examples, the remote control 140 can include wireless communication circuitry that enables wireless transmission of remote control signals (e.g., to the junction box and / or welding-type power supply 108). In some examples, a wireless receiver configured to communicate with the wireless communication circuitry can alternatively be coupled to the junction box 600 via a cable, rather than the remote control 140 itself being coupled to the junction box 600.

[0040] exist Figure 1 In the example of FIG. 1 , the GTAW welding torch 400 and the remote control 140 are selectively coupled to the welding-type power supply 108 through the junction box 600. As shown, the welding-type power supply 108 is also selectively coupled to the fixture 114 through the junction box 600. In some examples, the welding-type power supply 108 can be directly coupled to the fixture 114 via a cable. Although only one cable is shown for connecting the junction box 600 to the welding-type power supply 108 cable for simplicity, in some examples, the connection can be formed by multiple cables.

[0041] exist Figure 1 In the example of FIG. 1 , the clamp 114 is attached to the support platform 120 of the welding station 102 and the welding-type power supply 108. In some examples, the clamp 114 can be attached to the workpiece 110, some other part of the welding station 102, or some other device instead of being attached to the support platform 120. Although in Figure 1 108, but in some examples, the fixture 114 may instead be connected to the terminal box 600. During live welding, the support platform 120, the workpiece(s) 110, the fixture 114, the GTAW welding torch 400, and / or cables connecting the fixture 114 and / or the GTAW welding torch 400 to the welding-type power supply 108 may form a closed loop through which welding-type output power may be delivered.

[0042] exist Figure 1 In some examples, the welding-type power supply 108 includes (and / or is coupled to) a gas supply 142. In some examples, the gas supply 142 supplies a shielding gas and / or a shielding gas mixture to the GTAW welding torch 400. As used herein, a shielding gas can refer to any gas (e.g., CO2, argon) or gas mixture that can be provided to an arc and / or a weld pool to provide a specific local atmosphere (e.g., to protect the arc, improve arc stability, limit the formation of metal oxides, improve wetting of metal surfaces, change the chemical properties of the weld deposit, etc.).

[0043] exist Figure 1 In the example of FIG. 1 , the welding-type power supply 108 also includes an operator interface 144. Figure 1 In some examples, the operator interface 144 includes one or more adjustable inputs (e.g., knobs, buttons, switches, keys, etc.) and / or outputs (e.g., display screens, lights, speakers, etc.) on the welding power supply 108. In some examples, the operator 116 can use the operator interface 144 to input and / or select one or more welding parameters (e.g., voltage, current, gas type, wire feed speed, workpiece material type, filler type, etc.) and / or welding operations of the welding power supply 108. In some examples, the operator interface 144 can further include one or more sockets configured to connect to (and / or receive external memory devices) one or more external memory devices (e.g., floppy disks, compact disks, digital video disks, flash drives, etc.). In some examples, the operator 116 can additionally or alternatively use one or more input devices 130 of the welding station 102 and / or one or more torch inputs 416 of the GTAW welding torch 400 instead of the operator interface 144.

[0044] exist Figure 1 In an example of the welding-type power supply 108, the welding-type power supply 108 includes a power conversion circuit system 132, which is configured to receive input power (e.g., from a mains, a generator, etc.) and convert the input power into a welding-type output power. As shown, the welding-type power supply 108 further includes a control circuit system 134 electrically coupled to the power conversion circuit system 132 and / or configured to control the power conversion circuit system. In some examples, the control circuit system 134 may include a processing circuit system (and / or one or more processors) and analog and / or digital memory. In some examples, the control circuit system 134 is configured to control the power conversion circuit system 132, thereby ensuring that the power conversion circuit system 132 generates an appropriate welding-type output power to implement a target welding-type operation.

[0045] In some examples, the control circuit system 134 is also electrically coupled to a gas supply 142 and / or is configured to control the gas supply. In some examples, the welding-type power supply 108 can control the gas supply 142 to output a target type and / or amount of gas. For example, the control circuit system 134 can control a valve in communication with the gas supply 142 to regulate the gas delivered to the GTAW welding torch 400.

[0046] During the live arc mode of the GTAW training system, when the operator 116 activates the remote control 140, a live welding operation (and / or welding process and / or welding session) can be initiated. In such an example, one or more control signals indicating activation can be sent from the remote control 140 to the welding power supply 108 through the junction box 600. The control circuit system 134 of the welding power supply 108 can interpret the control signal and control the power conversion circuit system 132 to output the welding power based on (at least in part) the control signal. The welding power provided by the welding power supply 108 can be applied to the electrode 414 of the GTAW welding torch 400 so as to generate a welding arc between the electrode 414 and one or more workpieces 110. The heat of the arc can melt a portion of the electrode 112 and / or the workpiece 110, thereby generating a molten weld pool. Movement of the GTAW welding torch 400 and / or the electrode 112 (e.g., caused by the operator) can move the welding arc and / or the weld pool, thereby forming one or more welds 111. When the welding operation is completed, the operator 116 can deactivate the remote control 140.

[0047] During the simulation mode of the GTAW training system 100, when the operator 116 activates the remote control 140 and / or some other input of the GTAW training system 100 (e.g., the input device 130 and / or the torch input 416), a simulated welding operation (and / or welding process and / or welding session) can be initiated. In such an example, one or more control signals indicating activation can be sent from the remote control 140 to the junction box 600, which can forward the control signals to the training station 102 (while preventing the control signals from reaching the welding-type power supply 108, as discussed further below). The training station 102 can then simulate welding-type power, welding arc, molten weld pool, and / or other aspects of the welding operation. When the welding operation is completed, the operator 116 can deactivate the remote control 140.

[0048] In some examples, the junction box 600 and / or the welding-type power supply 108 can detect certain welding parameter data related to the welding-type power supply 108, the fixture 117, and / or the GTAW welding torch 400 during the welding process. In some examples, such welding parameter data can be transmitted to the welding station 102, which can use the welding parameter data for training analysis and / or feedback. In some examples, such transmission to the welding station 102 can occur in real time, periodically during the welding operation, and / or after the welding operation is completed.

[0049] exist Figure 1 In the example of the welding station 102, the welding station 102 includes a support platform 120 for providing support for one or more workpieces 110 and / or various training devices. In some examples, the support platform 120 may include slots and / or orifices to assist in positioning and / or orienting (multiple) workpieces 110. In some examples, (multiple) workpieces 110 may include an extension configured to extend into one or more slots and / or orifices to align the workpiece 110 with the one or more slots and / or orifices. In some examples, the position and / or orientation of (multiple) workpieces 110, slots and / or orifices can be used to calibrate the GTAW training system 100. For example, a calibration device configured to be sensed by one or more sensors 104 can be inserted into the orifice and / or slot, while a user input provided to the GTAW training system 100 indicates that the calibration device has been inserted into the orifice and / or slot. In some examples, the GTAW welding torch 400 and / or the electrode attachment 500 can be used as a calibration device. In some examples, the welding platform 120 may additionally or alternatively include one or more emitters configured to emit patterns onto the support platform 120, the workpiece 110, the GTAW welding torch 400, and / or the operator 116. The emitters may emit patterns in the infrared, visible, and / or ultraviolet spectrum for detection by the one or more sensors 104 to calibrate the position and / or orientation of the support platform 120 relative to the one or more sensors 104.

[0050] exist Figure 1 In some examples, the welding station 102 further includes an arm 126 that is connected to the support platform 120 and extends vertically from the support platform. A display monitor 128 having a display screen 129 is connected to the arm 126. In some examples, the display screen 129 can be configured to display welding training data and / or screens associated with welding training (e.g., corresponding to the GTAW training system 100). In some examples, a protective cover can be located above the display screen to prevent certain environmental elements (e.g., welding spatter, smoke, sparks, heat, etc.) from contacting the display screen 129. In some examples, the display monitor 128 can include additional output mechanisms, such as audio speakers.

[0051] exist Figure 1 In the example of , a stand 127 is also attached to the arm 126. The stand 127 supports several input devices 130 of the welding station 102. As shown, the input devices 130 include a mouse and a keyboard. In some examples, additional input devices 130 may be provided, such as one or more microphones. In some examples, the display screen 129 may be a touch screen and may further be considered an input device 130. In some examples, the torch input 416 of the GTAW welding torch 400 and / or the electrode attachment 500 may also be used as an input device 130.

[0052] exist Figure 1 In the example of , the welding station 102 further includes a sensor assembly 122 attached to the arm 126. As shown, the sensor assembly 122 includes a plurality of sensors 104a oriented toward the platform 120, the operator 116, the welding electrode 112, and / or the GTAW welding torch 400. In some examples, the sensor assembly 122 can be adjustable, such as via one or more knobs and / or other adjustment mechanisms. In some examples, the sensor assembly 102 (and / or the sensor 104a) can be configured to record sensor data related to objects in the welding environment (and / or the field of view of the sensor 104) during the welding operation.

[0053] exist Figure 1 In the example of , the GTAW training system 100 also includes several other sensors 104 configured to record sensor data related to objects in the welding environment (and / or in the field of view of the sensor 104). As shown, in addition to the sensor 104a, the GTAW training system 100 also includes a sensor 104b attached to the welding head 106 and a sensor 104c located around the welding environment. This arrangement of the sensors 104 can enable some sensors 104 to monitor the welding environment (e.g., track the movement of an object) when other sensors 104 are blocked.

[0054] In some examples, the sensor 104 may include, for example, a motion sensor, a depth sensor, a camera (e.g., an infrared camera, a visible spectrum camera, a high dynamic range camera, etc.), a sound sensor, a light sensor, and / or other suitable sensors. In some examples, the sensor data captured by the sensor 104 may include one or more images, videos, sounds, temperatures, radio waves, heat waves, radiation measurements, and / or other suitable data. In some examples, the sensor data may allow the welding station 102 to track, detect, and / or record the position, orientation, and / or movement of objects (e.g., an operator 116, a welding electrode 112, a welding electrode attachment 500, a GTAW welding torch 400, (multiple) workpieces 110, etc.) in the welding environment during a welding operation.

[0055] exist Figure 1In some examples, the workpiece 110 includes a marker 113 configured to be detected by one or more sensors 104 and / or tracked by the GTAW training system 100. In some examples, the support platform 120 may also include one or more markers built into and / or attached to the support platform to calibrate the position and / or orientation of the support platform 120 relative to the one or more sensors without a separate calibration device. In some examples, the marker 113 may be a passive marker, such as a reflective marker. In some examples, the marker 113 may be an active marker, such as a light-emitting marker (e.g., a light-emitting diode (LED)). In some examples, the marker 113, the torch marker 413, and / or the accessory marker 513 (and / or the sphere 520 / 530) can assist the GTAW training system 100 (e.g., via the sensor 104) in tracking the GTAW torch 400, the electrode 112, and / or the workpiece (s) 110, and / or determining the position and / or orientation of the GTAW torch 400, the electrode 112, and / or the workpiece (s) 110.

[0056] In some examples, the sensor 104 can be communicatively coupled to the training controller 200 of the welding station 102. For example, the sensor 104 can include a communication circuit system to facilitate wired and / or wireless communication with the training controller 200. In some examples, the sensor 104 is configured to provide sensor data (e.g., image data, sound data, sensed data, six degrees of freedom (6DOF) data, etc.) to the training controller 200, for example, via one or more signals. In some examples, the sensor 104 is further configured to receive data (e.g., configuration data, setting data, commands, register settings, etc.) from the training controller 200. Figure 1 In the example of FIG. 1 , the training controller 200 is disposed within the cabinet 121 of the welding station 102 .

[0057] exist Figure 2 In the example of FIG. 1 , the training controller 200 is coupled to and / or communicates with the sensor 104, the display monitor 128, the input device 130, and the junction box 600. As shown, the junction box 600 is further coupled to and / or communicates with the GTAW welding torch 400, the remote control 140, and the welding-type power supply 108. In some examples, the junction box 600 can be additionally coupled to and / or communicate with the fixture 114.

[0058] In some examples, training controller 200 may include analog and / or discrete circuit systems and / or one or more digital computing systems. Figure 2In some examples, training controller 200 includes memory circuitry 206, processing circuitry 204, and input / output (I / O) circuitry 202. In some examples, I / O circuitry 202 may include communication circuitry for communicating with other systems. In some examples, the communication circuitry may include one or more wireless adapters, wireless cards, cable adapters, line adapters, dongles, radio frequency (RF) devices, wireless communication devices, Bluetooth devices, IEEE 802.11 compliant devices, WiFi devices, cellular devices, GPS devices, Ethernet ports, network ports, lightning cable ports, cable ports, etc. In some examples, the communication circuitry may be configured to facilitate communication via one or more wired media and / or protocols (e.g., (multiple) Ethernet cables, (multiple) universal serial bus cables, etc.) and / or wireless media and / or protocols (e.g., near field communication (NFC), ultra-high frequency radio waves, IEEE 802.11x, Zigbee, HART, LTE, Z-Wave, Wireless HD, WiGig, etc.). In some examples, the I / O circuit system 202 may further include circuit systems for interfacing with various devices coupled to and / or communicating with the training controller 200 (such as, for example, a sensor 104, a GTAW welding torch 400, a remote control 140, a display monitor 128, a power supply 108, and / or an input device 130).

[0059] In some examples, processing circuitry 204 includes one or more processors for executing machine-readable instructions (and / or processor-executable instructions) stored in memory 206. In some examples, memory 206 stores machine-readable instructions that implement some or all of the functionality of various devices coupled to and / or in communication with training controller 200. Figure 2 In the example of FIG. , the memory 206 also stores a welding training program 300 .

[0060] Figure 3 is a flow chart illustrating an example welding training program 300 of the training controller 200. In some examples, the welding training program 300 may be implemented using machine-readable (and / or processor-executable) instructions stored in the memory 206 of the training controller 200 and / or executed by the processing circuit system 204. Figure 3In the example of FIG. 3 , the welding training program 300 starts at box 302. At box 302, the welding training program 300 performs certain setup and / or calibration operations. For example, the welding training program 300 can use sensor data from the sensor 104 to track one or more markers and / or calibration tools and perform necessary calibrations on the welding station 102, the GTAW welding torch 400, and / or the electrode accessory 500. As another example, the welding training program 300 can set the mode of the GTAW training system 100 in response to receiving one or more signals indicating a selection of a simulation mode or a live arc mode from the input device 130. As another example, the welding training program 300 can set the welding operation, welding training activity, setting, and / or parameter in response to receiving one or more signals indicating a selection of one or more welding operations, welding training activities, settings, and / or parameters from the input device 130. As another example, the welding training program 300 can access user information (and / or corresponding privileges, permissions, authorized welding operations / activities, etc.) in response to receiving one or more signals indicative of a user login and / or user credentials from the input device 130.

[0061] exist Figure 3 In the example of , the welding training program 300 continues to box 304 after box 302. At box 304, the welding training program 300 determines whether the welding session should start and / or has started. In some examples, the welding session may include one or more welding operations. In some examples, the welding session may be part of a welding training activity. In some examples, the determination at box 304 may include determining whether a welding session, welding training activity, and / or welding operation has been selected to start (e.g., via input device 130, GTAW welding torch 400, remote control 140, and / or operator interface 144). In some examples, the determination may include determining whether box 302 has been satisfactorily completed. In some examples, the determination may include determining whether the GTAW welding torch 400 has been activated (e.g., via remote control 140). If the welding training program 300 determines that the welding session should not start or has not started, the welding training program 300 returns to box 302. If the welding training program 300 determines that the welding session should start or has started, the welding training program 300 continues to box 306.

[0062] exist Figure 3In the example of FIG. 306 , the welding training program 300 tracks objects in the nearby welding environment (e.g., GTAW welding torch 400, welding electrode 112 and / or welding electrode accessory 500, (multiple) workpieces 110, welding station 102, operator 116, etc.). In some examples, the welding training program 300 can use sensor data received from sensors 104 (and / or sensing devices 105) to perform tracking. For example, sensors 104 can capture sensor data associated with the welding environment within their respective fields of view and transmit the sensor data to the training controller 200 via one or more data signals. The welding training program 300 can process the sensor data to detect, identify, and / or track objects. In some examples, the welding training program 300 can use markers 113, torch markers 413, and / or accessory markers 513 (and / or spheres 520 / 530) to detect, identify, and / or track objects.

[0063] exist Figure 3 In the example of , the welding training program 300 continues to box 307 after box 306. At box 307, the welding training program 300 determines the position and / or orientation of one or more objects (e.g., relative to other objects) in the welding environment. In some examples, the welding training program 300 can determine the position and / or orientation based on detection, identification, and / or tracking of objects via sensor data. For example, the welding training program 300 can determine one or more positions and / or orientations of the GTAW welding torch 400, the welding electrode 112, (multiple) workpieces 110, and / or the operator 116 relative to the support platform 120 and / or other elements of the GTAW training system 100 based on data captured by the sensor 104.

[0064] exist Figure 3In the example of FIG. 300 , the welding training program 300 continues to box 308 after box 307. At box 308, the welding training program 300 determines one or more parameters of the GTAW training system 100. In some examples, the one or more parameters may include one or more torch parameters (e.g., torch working angle, torch travel angle, torch travel speed, torch alignment, arc length, etc.), training parameters (e.g., tip to workpiece distance, cladding amount, porosity, penetration, etc.), welding parameters (e.g., voltage, current, gas flow / distribution, arc length, etc.), electrode parameters (e.g., electrode working angle, electrode travel angle, immersion rate / frequency / duration, oscillation shape / amplitude / frequency, etc.), and / or other related parameters. In some examples, the welding training program 300 can determine one or more parameters based on: the position and / or orientation determined at box 307; detection, identification and / or tracking of the object via data from the sensor 104 at box 306; data received from the detector 150 of the welding-type power supply 108; data received from one or more sensors of the junction box 600 (discussed further below); setup and / or calibration performed at box 302; and / or other relevant information.

[0065] exist Figure 3 In the example of , the welding training program 300 continues to box 310 after box 308. At box 310, the welding training program 300 determines whether the welding session has ended or should end. In some examples, the determination can include determining whether there is a selection to end the welding session and / or welding operation (e.g., via the input device 130, the remote control 140, and / or the operator interface 144). In some examples, the determination can include determining whether the GTAW welding torch 400 has been deactivated (e.g., via the remote control 140). If the welding training program 300 determines that the welding session has not ended or should not end, the welding training program 300 returns to box 306. If the welding training program 300 determines that the welding session has ended or should end, the welding training program 300 continues to box 312.

[0066] exist Figure 3In the example of , the welding training program 300 determines one or more training results at box 312. In some examples, the training results can be determined based on the parameters at box 312 (and / or the tracking data and / or position / orientation data of boxes 306 and 307). In some examples, the training results 208 may include one or more scores, grades, ratings, parameter sets, summaries of welding sessions (and / or welding operations, training activities, etc.), user (and / or operator 116, participant, etc.) information, and / or other welding training feedback related to the welding session (and / or (multiple) welding operations, training activities, etc.). In some examples, the training results may include two or more parameters synchronized over time. In some examples, the scores, grades, and / or ratings may be based at least in part on comparisons of these parameters with one or more parameters from previous welding sessions (and / or (multiple) welding operations, training activities, etc.). In some examples, previous welding sessions (and / or (multiple) welding operations, training activities, etc.) and / or associated parameters may be stored in the memory 206. In some examples, training controller 200 may associate the training results and / or parameters with the identity of operator 116 , such as via a unique number associated with operator 116 , the name of operator 116 , and / or other identification information of operator 116 .

[0067] At box 312, the welding training program 300 additionally outputs the training results 208. In some examples, outputting the training results can include outputting to the display screen 129 and / or other output mechanism of the GTAW training system 100. Although shown as being performed after the welding session ends at box 310, in some examples, box 312 can be performed before the welding session ends. For example, the welding training program 300 can continuously determine and / or output the training results 208 in real time during the welding session to enable live streaming. Figure 3 In the example of , the welding training program 300 ends after box 312.

[0068] Figure 6 It is shown Figure 1 A block diagram of the junction box 600 is provided in more detail for the components and connections. Figure 6 In the example of FIG. 6 , the junction box 600 includes an input device 602, an output device 604, a box sensor 606, a control switch 608, and a box control circuit system 610. As shown, the input device 602a is electrically connected to the training controller 200, while the input device 602b and the output device 604d are electrically connected to the welding-type power supply 108, and the input device 602c is fluidly connected to the welding-type power supply 108 (e.g., for delivering shielding gas). Figure 6As depicted on the other side of the junction box 600, output device 604a and output device 604b are electrically connected to the GTAW welding torch 400, while output device 604c is fluidly connected to the GTAW welding torch 400, and input device 602d is electrically connected to the remote control 140. Within the junction box 600, Figure 6 6, input device 602a and output device 604a are both electrically connected to cartridge control circuitry 610. Input device 602d is also depicted as being electrically connected to cartridge control circuitry 610. As shown, input device 602b and output device 604b are electrically connected to each other via power line 612. Likewise, input device 602c is shown as being fluidly connected to output device 604c via gas line 614.

[0069] exist Figure 6 In the example of , the input device 602d is selectively connected to the output device 604d through the switch 608. In some examples, the switch 608 may include one or more switches, relays, transistors and / or other controllable circuit elements. As shown, the switch 608 is electrically connected to the box control circuit system 610. In some examples, the switch 608 can couple or decouple the input device 602d and the output device 604d in response to one or more signals received from the box control circuit system 610. For example, the box control circuit system 610 can determine that the GTAW training system 100 is in live arc mode and send one or more signals indicating a closing command to the switch 608. In response, the switch 608 can be closed, thereby coupling the input device 602d and the output device 604d together, thereby allowing the signal from the remote control 140 to be transmitted from the input device 602d to the output device 604d, and then to the welding-type power supply 108. As a result, the welding-type power supply 108 may receive one or more signals from the remote control 140 for commanding the delivery of welding-type power and / or gas to the GTAW torch 400 (e.g., via the input device 602b, the output device 604b, the input device 602c, and / or the output device 604c). As another example, the box control circuit system 610 may determine that the GTAW training system 100 is in simulation mode and send one or more signals indicating a disconnect command to the switch 608. In response, the switch 608 may be disconnected, thereby decoupling the input device 602d and the output device 604d. As a result, the signal from the remote control 140 may not be transmitted from the input device 602d to the output device 604d and / or to the welding-type power supply 108. As a result, the welding-type power supply 108 may not receive any signal from the remote control 140 for commanding the delivery of welding-type power and / or gas to the GTAW torch 400, and therefore, in response, never transmit power or gas to the GTAW torch 400.

[0070] In some examples, the input device 602 and / or the output device 604 may include a conductive physical port (e.g., a male plug or a female socket). For example, the input device 602a may be a signal connection port configured to be electrically coupled to a signal cable that may be connected to the training controller 200 (and / or the welding station 102). Similarly, the output device 604a may be a signal connection port configured to be electrically coupled to a signal cable that may be connected to the GTAW welding torch 400. As another example, the output device 604d may be a signal connection port configured to be electrically coupled to a signal cable that may be connected to the welding-type power supply 108. Similarly, the input device 602d may be a signal connection port configured to be electrically coupled to a signal cable that may be connected to the remote control 140 (and / or a remote control receiver / transceiver).

[0071] In some examples, input device 602a and / or input device 602d may include input communication circuitry (e.g., one or more receivers, transceivers, and / or antennas) configured for wireless communication, rather than a physical port. In some examples, output device 604a and / or output device 604d may include output communication circuitry (e.g., one or more transmitters, transceivers, and / or antennas) configured for wireless communication, rather than a physical port. In such examples, the communication circuitry may be configured to wirelessly communicate with training controller 200, welding power supply 108, GTAW welding torch 400, and / or remote control 140 (and / or corresponding interoperable communication circuitry of training controller 200, welding power supply 108, GTAW welding torch 400, and / or remote control 140).

[0072] In some examples, the input device 602b may include a conductive physical power connection port (e.g., a male plug or a female socket) configured to electrically couple with a power cable connectable to the welding-type power supply 108. In some examples, the output device 604b may include a conductive physical power connection port (e.g., a male plug or a female socket) configured to electrically couple with a power cable connectable to the GTAW welding torch 400. In some examples, the input device 602b and / or the output device 604b may be configured to handle higher voltages, currents, and / or powers than the input device 602a, the input device 602d, the output device 604a, and / or the output device 604d.

[0073] In some examples, the input device 602c may include a physical gas connection port (male or female port) configured to couple with a gas cable that may be connected to the gas supply 142 of the welding-type power supply 108. In some examples, the output device 604c may include a physical gas connection port (male or female port) configured to couple with a gas cable that may be connected to the GTAW welding torch 400. In some examples, the input device 602c and / or the output device 604c may be omitted, and / or the gas may instead be delivered external to the junction box 600. Although in Figure 6 604d, input device 602b, and / or input device 602c may be combined into a single device and / or configured to connect to a single cable (e.g., a U.S. or European Dinse or Tweco style cable). Similarly, in some examples, output device 604b and / or output device 604c may be combined into a single device and / or configured to connect to a single cable (e.g., a U.S. or European Dinse or Tweco style cable).

[0074] exist Figure 6 In the example of FIG. 6 , the power line 612 electrically couples the input device 602b to the output device 604b. In some examples, the power line 612 can be configured to handle the high voltage and / or current welding power output by the welding power supply 108 for arc welding by the GTAW welding torch 400. As shown, the gas pipeline 614 fluidly couples the input device 602c and the output device 604c. Figure 6 In the example of FIG. 6 , the junction box 600 includes a voltage sensor 606a and a current sensor 606b electrically connected to the power line 612, and a gas flow sensor 606c in fluid communication with the gas pipeline 614. In some examples, the gas flow sensor 606c can be configured to sense, detect, and / or measure the gas flow through the gas pipeline 614. In some examples, the current sensor 606b can be configured to sense, detect, and / or measure the current through the power line 612.

[0075] In some examples, voltage sensor 606a can be configured to sense, detect, and / or measure the voltage on power line 612. Figure 6In the example of FIG. 6 , the voltage sensor 606a is electrically connected to the power line 612 and the electrical ground 616. Thus, in some examples, the voltage sensor 606a can sense, detect, and / or measure a voltage difference between the power line 612 and the electrical ground 616. In some examples, a second (clamp) power line (e.g., for the clamp 114) can be routed through the junction box 600, and the voltage sensor 606 can instead sense, detect, and / or measure a voltage difference between the GTAW torch power line 612 and the clamp power line.

[0076] exist Figure 6 In some examples, cartridge sensors 606 are electrically connected to cartridge control circuitry 610. In some examples, cartridge control circuitry 610 can receive one or more signals from cartridge sensors 606 indicating their detection and / or measurement values. In some examples, cartridge control circuitry 610 can send one or more control signals to cartridge sensors 606 to control their operation. In some examples, cartridge control circuitry 610 can transmit the detection and / or measurement values ​​of cartridge sensors 606 to training controller 200 via input device 602a.

[0077] exist Figure 6In the example of FIG. 6 , the cartridge control circuit system 610 is also electrically connected to the input device 602a, the output device 604a, and the input device 602d. In some examples, the input device 602a and the output device 604a can function as both input devices and output devices, in which case they can serve as conduits for both output signals from the cartridge control circuit system 610 (e.g., to the training controller 200 and / or the GTAW welding torch 400) and input signals to the cartridge control circuit system 610 (e.g., from the training controller 200 and / or the GTAW welding torch 400). For example, the cartridge control circuit system 610 can transmit a control signal received from the remote control 140 via the input device 602d to the training controller 200 through the input device 602a (e.g., so that the training controller 200 can detect an activation signal, etc.). Because the cartridge control circuitry 610 is electrically connected to the input device 602d, the cartridge control circuitry 610 is able to receive control signals from the remote control 140 regardless of whether the GTAW training system 100 is in live arc mode or simulation mode (and / or regardless of the corresponding state of the switch 608). Thus, the input device 602a can function as both an input device and an output device, in which case it can function as a conduit for both input signals from the training controller 200 and output signals to the training controller 200. As another example, the cartridge control circuitry 610 can communicate the mode state (e.g., live arc or simulation) to the GTAW torch 400 via the output device 604a, so that the GTAW torch 400 can provide a corresponding indication via the torch output 418. In addition, the GTAW torch 400 can send one or more control signals to the cartridge control circuitry 610 via the output device 604a, the control signals indicating a certain operator selection (e.g., live arc mode or simulation mode) made via the torch input 416. Thus, the output device 604a can act as both an input device and an output device, in which case it can act as a conduit for both input signals from the GTAW welding torch 400 and output signals to the GTAW welding torch 400.

[0078] exist Figure 6 In some examples, the cartridge control circuitry 610 includes a cartridge processing circuitry 620 and a cartridge memory circuitry 622. In some examples, the cartridge processing circuitry 620 may include one or more processors. In some examples, the cartridge memory circuitry 622 may store machine-readable (and / or processor-executable) instructions. In some examples, the cartridge control circuitry 610 (and / or the cartridge memory circuitry 622 and / or the cartridge processing circuitry 624) may include discrete and / or analog circuitry.

[0079] Figure 7A flow chart illustrating an example cartridge control method 700 is shown. As shown, cartridge control method 700 illustrates the operation of cartridge control circuitry 610. In some examples, a portion or all of cartridge control method 700 may be implemented using machine-readable instructions stored in cartridge memory circuitry 622 and / or executed by cartridge processing circuitry 620 of junction box 600. In some examples, a portion or all of cartridge control method 700 may be implemented in analog and / or discrete circuitry.

[0080] exist Figure 7 In the example of FIG. 7 , the cartridge control method 700 begins at block 702, where the cartridge control circuit system 610 receives input from the GTAW torch 400 via an output device 604a. In some examples, the input may be one or more signals sent from the GTAW torch 400 in response to input received via a torch input 416. For example, one or more torch inputs 416 may be used to command a particular mode (e.g., live arc mode or simulation mode). The cartridge control circuit system 610 may process the input and / or forward it to the training controller 200 via the input device 602a. After block 702, the method 700 continues to block 704, where the cartridge control circuit system 610 determines a mode (e.g., live arc or simulation) of the GTAW training system 100. In some examples, the determination may be made based on one or more signals received from the training controller 200 via the input device 602a. For example, the training controller 200 may change the mode based on input from the GTAW welding torch 400 and / or send one or more signals indicating the mode to the cartridge control circuitry 610 via the input device 602a. Alternatively, the training controller 200 may send one or more signals indicating that the mode has not changed despite input from the GTAW welding torch 400 (e.g., where the GTAW training system 100 is no longer in a setup / calibration phase or other appropriate phase).

[0081] exist Figure 7, the method 700 continues to block 706 after block 704. At block 706, the method 700 determines whether the mode is a live arc mode. If the GTAW training system 100 is in the live arc mode, the method continues to block 708, where the box control circuit system 610 sends one or more control signals to close the switch 608. Closing the switch 608 couples the input device 602d to the output device 604d and enables the welding-type power supply 108 to receive signals from the remote control 140. If the GTAW training system 100 is not in the live arc mode, the method continues to block 710, where the box control circuit system 610 sends one or more control signals to open the switch 608, thereby decoupling the input device 602d from the output device 604d and disabling the welding-type power supply 108 from receiving signals from the remote control 140. Although block 706 is depicted as determining whether the GTAW training system 100 is in live arc mode, in some examples, block 706 may alternatively or additionally include determining whether the GTAW training system 100 is in simulation mode or other mode. After blocks 708 and / or 710, the method continues to block 711.

[0082] exist Figure 7 In the example of FIG. 7 , at block 711, the method 700 processes and / or analyzes one or more control signals received from the remote control 140 (e.g., via the input device 602d), and / or sends one or more control signals to the training controller 200. As shown, the control signals are sent to the training controller 200 regardless of whether blocks 708 or 710 are executed. Thus, the welding training program 300 of the training controller 200 can use the remote control signal(s) regardless of whether the GTAW training system 100 is in live arc mode, simulation mode, or some other mode (and / or whether the switch 608 is open or closed). After block 711, the method 700 continues to block 712.

[0083] exist Figure 7 In the example of FIG. 7 , method 700 processes and / or analyzes the data received from cartridge sensor 606 at block 712 and / or sends the cartridge sensor data to training controller 200. In some examples, training controller 200 may use the cartridge sensor data to determine one or more parameters (e.g., Figure 3 308 of ) and / or training results (e.g., in Figure 3312 of FIG. 1 ). As shown, the method 700 continues to box 714 after box 712. At box 714, the method 700 sends one or more control signals to the GTAW torch 400 via the output device 604a to control the torch markings 413, the torch output 418, and / or the feedback mechanism 420. For example, the box control circuit system 610 can control the activation and / or deactivation of one or more torch markings 413 (and / or multiple groups of torch markings 413) for detection and / or tracking by the GTAW training system 100. In some examples, the box control circuit system 610 can use one or more signals received from the training controller 200 to determine how to control the torch markings 413. For example, the training controller 200 can provide one or more signals indicating data captured by the sensor 104 and / or tracking operation to the box control circuit system 610, and the box control circuit system 610 can control the torch markings 413 based on the one or more signals. As another example, the cartridge control circuitry 610 may activate and / or deactivate one or more torch outputs 418 to indicate a mode of the GTAW training system 100 and / or whether the GTAW training system 100 is in a state in which the mode may be changed. As yet another example, the cartridge control circuitry 610 may send one or more signals indicating a command to activate / deactivate (and / or operate at a certain level) to the feedback mechanism 420, such as in response to one or more parameters and / or training results transmitted by the training controller 200. Although the method 700 is depicted as ending after block 714, in some examples, the method 700 may restart at block 702 after ending.

[0084] The present disclosure describes a GTAW training system 100 that uses torch markings 413, electrode attachments 500 with attachment markings 513, and a terminal box 600 to facilitate training in the unique circumstances of a gas tungsten arc welding system. Given the scarcity of welding expertise in the industry and the unique nature of GTAW welding, training systems such as the disclosed GTAW training system 100 play an important role. Additionally, the ability of a GTAW training system to operate in both live arc mode and simulation mode means that one can hone their skills in a simulated environment before engaging in real live welding and gain valuable feedback for both modes.

[0085] The method and / or system can be implemented with hardware, software, or a combination of hardware and software. The method and / or system can be implemented in a centralized manner in at least one computing system, or in a distributed manner with different elements spread over several interconnected computing systems or cloud systems. Any type of computing system or other device suitable for executing the method described herein is suitable. A typical combination of hardware and software can be a general computing system with a program or other code, which controls the computing system when loaded and executed so that the computing system executes the method described herein. Another typical implementation may include a dedicated integrated circuit or chip. Some implementations may include a non-temporary machine-readable (e.g., computer-readable) medium (e.g., a flash drive, an optical disk, a magnetic storage disk, etc.), which stores one or more lines of code executable by a machine, so that the machine executes the process described herein.

[0086] Although the present method and / or system has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present method and / or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope of the present disclosure. Therefore, the present method and / or system is not intended to be limited to the particular embodiments disclosed, but rather the present method and / or system will include all embodiments falling within the scope of the appended claims.

[0087] As used herein, "and / or" refers to any one or more of the items connected by "and / or" in a list. For example, "x and / or y" refers to any element in the three-element set {(x), (y), (x, y)}. In other words, "x and / or y" means "one or both of x and y". As another example, "x, y and / or z" refers to any element in the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, "x, y and / or z" means "one or more of x, y and z".

[0088] As used herein, the terms "for example" and "such as" introduce a list of one or more non-limiting examples, instances, or illustrations.

[0089] As used herein, the terms "coupled," "coupled to," and "coupled with" refer to structural and / or electrical connections, whether attached, attached, connected, combined, fastened, associated, and / or otherwise secured, respectively. As used herein, the term "attach" refers to attaching, coupling, connecting, combining, fastening, associated, and / or otherwise securing. As used herein, the term "connect" refers to attaching, attaching, coupling, combining, fastening, associated, and / or otherwise securing.

[0090] As used herein, the terms "circuit" and "circuitry" refer to physical electronic components (i.e., hardware) and any software and / or firmware ("code") that may configure, be executed by, and / or otherwise be associated with the hardware. As used herein, for example, a particular processor and memory may constitute a first "circuit" when executing a first one or more lines of code, and may constitute a second "circuit" when executing a second one or more lines of code. As used herein, a circuitry is "operable" and / or "configured" to perform a function when the circuitry includes the hardware and / or code (if necessary) necessary to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory adjustment, etc.).

[0091] As used herein, control circuitry (and / or control circuitry) may include digital circuitry and / or analog circuitry, discrete circuitry and / or integrated circuitry, microprocessors, DSPs, etc., located on one or more boards forming part or all of a controller and / or software, hardware and / or firmware for controlling a welding process, and / or devices such as a power supply or a wire feeder.

[0092] As used herein, the term "processor" refers to a processing device, apparatus, program, circuit, component, system and subsystem, whether implemented in hardware, tangibly embodied software or both hardware and software, and whether or not it is programmable. As used herein, the term "processor" includes, but is not limited to, one or more computing devices, hard-wired circuits, signal modification devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field programmable gate arrays, application-specific integrated circuits, systems on chips, systems including discrete components and / or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general-purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC), a graphics processing unit (GPU), a reduced instruction set computer (RISC) processor with an advanced RISC machine (ARM) core, and the like. The processor may be coupled to a memory device and / or integrated with a memory device.

[0093] As used herein, the terms "memory" and / or "memory device" refer to computer hardware or circuitry for storing information for use by a processor and / or other digital device. The memory and / or memory device may be any suitable type of computer memory or any other type of electronic storage medium, such as read-only memory (ROM), random access memory (RAM), cache memory, compact disk read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), computer-readable media, etc. The memory may include, for example, non-transitory memory, non-transitory processor-readable medium, non-transitory computer-readable medium, non-volatile memory, dynamic RAM (DRAM), volatile memory, ferroelectric RAM (FRAM), first-in-first-out (FIFO) memory, last-in-first-out (LIFO) memory, stack memory, non-volatile RAM (NVRAM), static RAM (SRAM), cache, swap memory, semiconductor memory, magnetic memory, optical memory, flash memory, flash memory card, compact flash memory card, memory card, secure digital memory card, micro card, mini card, expansion card, smart card, memory stick, multimedia card, picture card, flash memory device, subscriber identity module (SIM) card, hardware drive (HDD), solid state drive (SSD), etc. The memory may be configured to store code, instructions, applications, software, firmware and / or data, and may be provided outside the processor, inside the processor, or both outside and inside the processor.

[0094] For convenience, the term "power" is used throughout this specification, but it also includes related measurements such as energy, current, voltage, and enthalpy. For example, controlling "power" may involve controlling voltage, current, energy, and / or enthalpy, and / or controlling based on "power" may involve controlling based on voltage, current, energy, and / or enthalpy.

[0095] As used herein, welding-type power refers to power suitable for: welding, cladding, brazing, plasma cutting, induction heating, carbon arc cutting and / or hot wire welding / preheating (including laser welding and laser cladding), carbon arc cutting or scraping, and / or resistive preheating.

[0096] As used herein, a welding-type power supply and / or power source refers to any device that is capable of providing power for welding, cladding, brazing, plasma cutting, induction heating, laser processing (including laser welding, laser composite processing, and laser cladding), carbon arc cutting or scraping, and / or resistive preheating when power is applied thereto, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuit systems and other auxiliary circuit systems associated therewith.

Claims

1. A junction box for a gas tungsten arc welding (GTAW) training system, the junction box comprising: a remote control input device configured to receive a remote control signal from a remote controller; a remote control output device configured to provide the remote control signal to a welding-type power supply; a welding torch connection device configured for electrical connection with a GTAW welding torch; a switch configured to selectively couple the remote control input device to the remote control output device; as well as A control circuit system, the control circuit system being configured to: providing a training signal representing the remote control signal to a welding training controller; in a live arc mode, controlling the switch to selectively couple the remote control input device to the remote control output device to enable the remote control signal to be transmitted to the welding-type power supply; In a simulation mode, controlling the switch to selectively decouple the remote control input device from the remote control output device to prevent the remote control signal from being transmitted to the welding-type power supply; and One or more torch output signals are provided to the GTAW welding torch via the torch connection device.

2. The junction box according to claim 1, wherein: The remote control input device includes an input port or input communication circuitry, and the remote control output device includes an output port or output communication circuitry.

3. The junction box according to claim 1, wherein: The remote controller includes a foot pedal.

4. The junction box according to claim 1, wherein: The switch includes a relay.

5. The junction box of claim 1, further comprising: a power input port configured to receive welding-type power from the welding-type power supply; as well as A power output port is configured to provide the welding-type power to the GTAW welding torch, the power input port and the power output port being electrically connected via a power line.

6. The junction box of claim 5, further comprising: A sensor is electrically connected to the control circuitry and the power line, the sensor being configured to detect a current or a voltage on the power line.

7. The junction box according to claim 6, wherein: The control circuitry is further configured to provide a signal representative of the current or voltage to the welding training controller.

8. The junction box according to claim 1, wherein: The control circuit system is further configured to receive one or more torch input signals from the GTAW welding torch via the torch connection device, the one or more torch input signals representing a selection of the live arc mode or the simulation mode.

9. The junction box of claim 1, further comprising: A training connection device configured to be electrically connected to the welding training controller, the control circuit system being configured to provide a training output signal to the welding training controller via the training connection device, wherein the control circuit system is further configured to receive one or more training input signals from the welding training controller via the training connection device, the one or more training input signals representing the live arc mode or the simulation mode.

10. A method for operating a junction box of a GTAW training system, the method comprising: receiving a remote control signal from a remote control of a GTAW welding torch via a remote control input device of the junction box; providing a training signal representing the remote control signal to a welding training controller via a training connection device of the junction box; providing the remote control signal to a welding-type power supply in a live arc mode; In simulation mode, preventing the remote control signal from being provided to the welding-type power supply; and One or more torch input signals are received from the GTAW welding torch via a torch connection device of the junction box.

11. The method of claim 10, further comprising receiving a mode signal from the welding training controller via the training connection device, the mode signal indicating the live arc mode or the simulation mode.

12. The method of claim 10, wherein: Providing the remote control signal to the welding-type power supply includes controlling a switch of the junction box to selectively couple the remote control input device to a remote control output device of the junction box, the remote control output device being configured to couple to the welding-type power supply.

13. The method of claim 10, wherein: Preventing the remote control signal from being provided to the welding-type power supply includes controlling a switch to selectively decouple the remote control input device from a remote control output device of the junction box, the remote control output device being configured to couple to the welding-type power supply.

14. The method of claim 10, wherein: The remote controller includes a foot pedal.

15. The method of claim 10, further comprising sending the one or more torch input signals to the welding training controller via the training connection device, the one or more torch input signals representing a selection of the live arc mode or the simulation mode.

16. The method of claim 10, further comprising controlling one or more torch output indicators of the GTAW welding torch via the torch connection device of the junction box.

17. The method of claim 10, further comprising controlling one or more torch markings of the GTAW welding torch via the torch connection device of the junction box.

18. The method of claim 10, further comprising measuring, via a sensor, a current or voltage on a power line of the junction box, the power line being electrically connected to a power port configured for electrical connection to the welding-type power supply.

19. The method of claim 18, further comprising sending one or more signals representative of the current or voltage to the training controller via the training connection device.

20. A junction box for a gas tungsten arc welding (GTAW) training system, the junction box comprising: Junction box housing; a power input port configured for connection to a welding-type power supply; a power output port configured for connection to a GTAW welding torch; a power line, the power line always connecting the power input port and the power output port together, the power line being accommodated in the junction box housing; a remote control input device configured to receive remote control signals from a remote control for the GTAW welding torch, the remote control input device being at least partially housed within the junction box housing; a remote control output device configured to provide the remote control signal received at the remote control input device to the welding-type power supply when the remote control output device is coupled to the remote control input device, the remote control output device being at least partially housed within the junction box housing; a switch configured to selectively couple the remote control input device to the remote control output device, the switch being housed within the junction box housing; as well as a control circuit system, the control circuit system being electrically connected to the remote control input device, the control circuit system being accommodated in the junction box housing, The control circuit system is configured to: receiving the remote control signal from the remote control input device; providing a training signal representing the remote control signal to a welding training controller; in a live arc mode, controlling the switch to selectively couple the remote control input device to the remote control output device to enable the remote control signal to be transmitted to the welding-type power supply; and In the simulation mode, the switch is controlled to selectively decouple the remote control input device from the remote control output device to prevent the remote control signal from being transmitted to the welding-type power supply.

21. The junction box of claim 20, further comprising: a gas input port configured to receive a shielding gas from a gas supply, the gas input port being at least partially housed within the junction box housing; a gas output port configured to provide the shielding gas to the GTAW welding torch, the gas output port being at least partially housed within the junction box housing; as well as A gas pipeline connects the gas input port to the gas output port, the gas pipeline being accommodated within the junction box housing.

22. The junction box of claim 21, further comprising: A gas sensor is configured to measure the gas flow of the shielding gas passing through the gas pipeline, the gas sensor is accommodated in the junction box housing, the gas sensor is electrically connected to the control circuit system, and the control circuit system is further configured to provide a signal representing the gas flow to the welding training controller.

23. A method for operating a terminal box of a GTAW training system, the method comprising: receiving a remote control signal from a remote control of a GTAW welding torch at the junction box via a remote control input device of the junction box, the GTAW welding torch being separate from the junction box and the remote control input device being at least partially housed within a junction box housing of the junction box; providing a training signal representative of the remote control signal from the junction box to a welding training controller via a training connection device of the junction box, the training connection device being at least partially housed within the junction box housing; determining a mode of the GTAW training system using control circuitry of the junction box, the control circuitry being housed within the junction box housing; as well as providing the remote control signal to the welding-type power supply by controlling a switch of the junction box to selectively couple the remote control input device to the remote control output device of the junction box in a live arc mode, the switch being housed within the junction box housing, and preventing the remote control signal from being provided to the welding-type power supply by controlling the switch to selectively decouple the remote control input device from the remote control output device of the junction box in a simulated mode; as well as The current or voltage on the power line of the junction box is measured via a sensor of the junction box accommodated in the junction box housing, the power line is accommodated in the junction box housing, the power line always connects the power input port of the junction box and the power output port of the junction box together, the power input port is configured to be electrically connected to the welding-type power supply, and the power output port is configured to be electrically connected to the GTAW welding torch.

24. The method of claim 23, further comprising measuring a gas flow through a gas line of the junction box via a sensor of the junction box, the gas line and the sensor being housed within the junction box housing, the gas line connecting a gas input port of the junction box with a gas output port of the junction box, the gas output port being configured for connection to the GTAW welding torch.

25. The method of claim 24, further comprising sending one or more signals representative of the gas flow to the training controller via the training connection device.

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