Tungsten Inert Gas Arc Welding Training System

Abstract

Systems and methods for a gas tungsten arc welding (GTAW) training system are described. In some examples, the GTAW training system includes a GTAW torch and an electrode holder having one or more markers to facilitate detection and / or tracking of the position and / or orientation of the GTAW torch and the electrode. One or more sensors of the GTAW training system can be configured to capture data related to the markers of the GTAW torch and / or the electrode holder. A training controller of the GTAW training system can use the markers and / or sensor data to track and / or determine the position, orientation, and / or movement of the GTAW torch and / or the electrode. The position, orientation, and / or movement can be analyzed in conjunction with welding parameter data to provide training feedback.

Description

Technical Field

[0001] The present disclosure generally relates to a gas tungsten arc welding training system. Background Art

[0002] The welding industry lacks experienced and skilled operators. Additionally, 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 enable both experienced and inexperienced welding operators to practice to produce high-quality welds.

[0003] The limitations and disadvantages of conventional and traditional methods will become apparent to those skilled in the art when compared with this disclosure, which is set forth in the remainder of the application with reference to the accompanying drawings. Summary of the Invention

[0004] The present disclosure relates to a gas tungsten arc welding (GTAW) training system substantially as shown in at least one of the drawings and / or described in conjunction with at least one of the drawings and 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 the illustrated examples of the present disclosure, will be more fully understood from the following specification, claims, and drawings. Brief Description of the Drawings

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

[0007] Figure 2 is a further illustration of an example of Figure 1 the components of a GTAW training system in accordance with aspects of the present disclosure.

[0008] Figure 3 is a flowchart of an example GTAW training program that can be used with Figure 1 the GTAW training system in accordance with aspects of the present disclosure.

[0009] Figure 4 An example GTAW torch that can be used in Figure 1 the example GTAW training system in accordance with aspects of the present disclosure is shown.

[0010] FIG. 5a shows an example electrode and electrode attachment that can be used in Figure 1 the example GTAW training system in accordance with aspects of the present disclosure.

[0011] FIG. 5b shows an example that can be used inFigure 1 Another example electrode and electrode attachment used in the exemplary GTAW training system.

[0012] FIG. 5c shows another example electrode and electrode attachment that can be used in an exemplary GTAW training system in accordance with aspects of the present disclosure. Figure 1 Another example electrode and electrode attachment used in the exemplary GTAW training system.

[0013] Figure 6 is a block diagram showing the interrelationship of example components of a junction box of a GTAW training system in accordance with aspects of the present disclosure Figure 1 and other components of the GTAW training system. Figure 1

[0014] Figure 7 is a flowchart illustrating an example box control method that can be used with a junction box in accordance with aspects of the present disclosure. Figure 6

[0015] The drawings are not necessarily to scale. Where appropriate, the same or similar reference numerals are used to denote similar or identical elements in the drawings. For example, reference numerals with letters (e.g., sensor 104a, sensor 104b) are used to denote instances of the same reference numeral without the letter (e.g., sensor 104). Detailed Description

[0016] Some examples of the present disclosure relate to a gas tungsten arc welding (GTAW) training system that includes: a GTAW torch that includes a first set of visual markers; an attachment configured to be attached to an electrode, the attachment including a second set of visual markers; one or more sensors configured to detect the first set of visual markers and the second set of visual markers; and a control circuitry in communication with the one or more sensors, the control circuitry being configured to: determine a first position or a first orientation of the GTAW torch based on detection of the first set of visual markers by the one or more sensors; and determine a second position or a second orientation of the electrode based on detection of the second set of visual markers by the one or more sensors.

[0017] ​​In some examples, the control circuitry is further configured to determine one or more torch parameters based on a first position or a first orientation of the GTAW torch, and to determine one or more electrode parameters based on a second position or a second orientation of the electrode. In some examples, the one or more torch parameters include one or more of a working angle or a travel angle of the GTAW torch. In some examples, the one or more electrode parameters include one or more of a working angle, an immersion parameter, or a travel angle of the electrode. In some examples, the control circuitry is further configured to determine the one or more torch parameters based on the first position or the first orientation of the GTAW torch, and to determine the one or more electrode parameters based on the second position and the second orientation of the electrode, wherein the one or more torch parameters include an arc length, a travel speed, or an alignment of the GTAW torch, and the one or more electrode parameters include one or more immersion parameters, one or more weaving parameters, an alignment of the electrode, a working angle of the electrode, or a travel angle of the electrode.

[0018] In some examples, the system further includes a display screen, and the control circuitry is further configured to display, on the display screen, a graphical representation of the one or more torch parameters and the one or more electrode parameters that is time-synchronized with welding parameter data. In some examples, the control circuitry is configured to determine a vector based on detection of the second set of visual markers, and the control circuitry is further configured to determine the one or more electrode parameters based on the vector. In some examples, the attachment includes an object having a plurality of flat interconnecting surfaces, the object having a through-hole configured to receive the electrode. In some examples, the attachment includes two spherical markers connected together. In some examples, the second set of visual markers is arranged in a manner that defines a rigid body.

[0019] Some examples of the present disclosure relate to a method of operating a gas tungsten arc welding (GTAW) system, the method comprising: detecting, via one or more sensors, a first set of visual markers of a GTAW torch; detecting, via the one or more sensors, a second set of visual markers of an attachment attached to an electrode; determining, via a control circuitry, a first position or a first orientation of the GTAW torch based on detection of the first set of visual markers by the one or more sensors; and determining, via the control circuitry, a second position or a second orientation of the electrode based on detection of the second set of visual markers by the one or more sensors.

[0020] In some examples, the method further includes: via the control circuitry, determining one or more torch parameters based on a first position or a first orientation of the GTAW torch, and via the control circuitry, determining one or more electrode parameters based on a second position or a second orientation of the electrode. In some examples, the one or more torch parameters include one or more of a working angle or a travel angle of the GTAW torch. In some examples, the one or more electrode parameters include one or more of a working angle, an immersion parameter, or a travel angle of the electrode. In some examples, the method further includes: time-synchronizing the one or more torch parameters and the one or more electrode parameters with welding parameter data. In some examples, the one or more torch parameters are determined based on a first position or a first orientation of the GTAW torch, and the one or more electrode parameters are determined based on a second position and a second orientation of the electrode, wherein the one or more torch parameters include an arc length, a travel speed, or the alignment of the GTAW torch, and the one or more electrode parameters include one or more immersion parameters, one or more weaving parameters, the alignment of the electrode, the working angle of the electrode, or the travel angle of the electrode.

[0021] In some examples, the method further includes: displaying, on a display screen, a graphical representation of the one or more torch parameters and the one or more electrode parameters time-synchronized with the welding parameter data. In some examples, the attachment includes an object having a plurality of flat interconnecting surfaces, the object having a through-hole configured to receive the electrode. In some examples, the attachment includes two spherical markers connected together. In some examples, the one or more sensors include one or more cameras.

[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 "gun" also manipulates the filler material. Therefore, changing the position and / or orientation of the "torch" or "gun" also changes the position and / or orientation of the filler material. In the GTAW system, the filler material is separate from the torch or gun (and / or manipulated separately). Therefore, changing the position and / or orientation of the "torch" or "gun" does not change the position and / or orientation of the filler material. Additionally, the filler material in GMAW and / or SMAW systems also serves as the electrode, while the filler material in the GTAW system is completely separate from the electrode. Furthermore, in GMAW and / or SMAW systems, the electrical power used to generate the arc is typically continuous (e.g., in the case of SMAW) or activated via a trigger on the torch or gun (e.g., in the case of GMAW). In the GTAW system, the electrical power used to generate the arc can be activated (and / or incrementally controlled) using a remote control (e.g., a foot pedal) that is separate from both the 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 torch and a filler rod attachment that have one or more markers to facilitate detecting and / or tracking the position and / or orientation of the GTAW torch and the filler rod. One or more sensors of the GTAW training system are configured to capture data related to the markers of the GTAW torch and / or the filler rod attachment. The training controller of the GTAW training system can use the markers and / or sensor data to track and / or determine the position, orientation, and / or movement of the GTAW torch and / or the filler rod. The position, orientation, and / or movement can be analyzed in combination with welding parameter data to provide training feedback.

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

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

[0026] Figure 5A An example of the welding rod attachment 500a of the GTAW training system 100 is shown. In Figure 5A the example, the welding rod attachment 500a includes a cuboid 502. As shown, the cuboid 502 has a number of flat interconnected surfaces. Although shown as a cuboid 502 in Figure 5A the example, in some examples, the welding rod attachment 500a may be an object of a different shape with a number of flat interconnected surfaces. As shown, the cuboid 502 has an aperture 504 on one surface. As shown, the aperture 504 leads to a channel 506 that extends partially through the cuboid 502 and terminates at or before the end 508 of the cuboid 502. In some examples, the size of the aperture 504 and / or the channel 506 is set to comfortably and / or tightly accommodate a portion of the welding rod 112 so as to hold the welding rod attachment 500a frictionally on the welding rod 112.

[0027] In Figure 5A the example, the cuboid 502 includes a number of attachment markers 513. As shown, the attachment markers 513 are passive markers, such as reflectors. In some examples, the attachment markers 513 may also be active markers, such as light-emitting diodes (LEDs). In Figure 5AIn the example of , two attachment markers 513 are provided on each face of the cuboid 502. In some examples, more or fewer attachment markers 513 may be provided on each face. In some examples, the distance between any two attachment markers 513 (e.g., 513a and 513c / 513d, or 513b and 513c / 513d) on adjacent faces of the cuboid 502 may be unique compared to the distance between two attachment markers 513 (e.g., 513a and 513b) on each identical face of the cuboid 502. In this way, the GTAW training system 100 can determine which attachment markers 513 are on the same face of the cuboid 502 by comparing the distances between the attachment markers 513, and thus determine which pair (and / or which set) of attachment markers 513 defines an axis parallel to the axis of the welding electrode 112. Once the parallel axis is known, the GTAW training system 100 can project this axis onto 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 at which the welding 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 attachment markers 513 may be arranged in a manner that forms a rigid body, and the GTAW training system 100 can use this rigid body to determine both the relative position and orientation.

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

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

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

[0031] Figure 4 Shows Figure 1 an enlarged view of an example GTAW torch 400 of an example GTAW training system 100. In Figure 4 the example, the GTAW torch 400 includes a head 402 connected to a handle 406 via a neck 404. In some examples, the neck 404 may be rigid. In some examples, the neck 404 may be flexible to allow the head 402 to be reoriented and / or adjusted relative to the handle 406. As shown, the 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 may be separate from the GTAW torch 400 such that the body 408 can be detached from and / or attached to different torches.

[0032] In Figure 4In the example of, the tungsten electrode 414 extends from the nozzle 410. Inside the nozzle 410, the tungsten 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 torch 400. Inside the GTAW torch 400, welding-type power can be delivered to the tungsten electrode 414 to form an arc. Similarly, gas can be delivered to the torch nozzle 410 to be dispensed near the arc. In some examples, the GTAW torch 400 can be configured as a mock torch that cannot perform actual welding and does not require the tungsten electrode 414.

[0033] In Figure 4 the example of, the head 402 includes a number of torch markers 413 attached to the body 408. By attaching the torch markers 413 to the body 408 (and / or the head 402), a fixed spatial relationship between the torch markers 413 and the tungsten electrode 414 can be ensured even if the position / orientation of the head 402 is reoriented and / or adjusted via the neck 404 relative to the handle 406. In some examples, the GTAW training system 100 can use this 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, a fixed arrangement of the torch markers 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 markers 413 can allow the GTAW training system 100 to determine the position and orientation of the GTAW torch 400. Although in Figure 4 the example of, all the torch markers 413 are in one group, in some examples, the torch markers 413 can be arranged in multiple groups, where each group has at least three torch markers 413 (to define a rigid body). In some examples, multiple groups of torch markers 413 can facilitate consistent and / or robust tracking through a variety of angles and orientations. In some examples, the torch markers 413 can be included in or held within holes, cavities, sockets, and / or other structures in the body 408.

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

[0036] In Figure 4 the example of, the GTAW torch 400 includes a torch input 416, a torch output 418, and a feedback mechanism 420. Although two torch inputs 416 and two torch outputs 418 are shown in Figure 4 the example of, in some examples, the GTAW torch 400 can include more or fewer torch inputs 416 and / or torch outputs 418. In some examples, the torch input 416 can include buttons, switches, dials, knobs, microphones, and / or other suitable input mechanisms. In some examples, the torch output 418 can include visual outputs (e.g., display screens, lights, etc.) and / or audio outputs (e.g., speakers). In some examples, the feedback mechanism 420 can include a haptic feedback mechanism and / or a vibration mechanism.

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

[0038] In some examples, the operator 116 may use the torch input 416, the torch output 418, and / or the feedback mechanism 420 to provide input to the GTAW training system 100 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 may use one or more of the torch inputs 416 to select a live arc mode or a simulation mode. In such an example, the GTAW torch 400 may 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 may send one or more signals indicating the mode (e.g., live arc or simulation) to the GTAW torch 400, and one or more of the torch outputs 418 may provide an appropriate mode indication to the operator 116. As another example, the junction box 600 (and / or the torch circuitry 422) may 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] In Figure 1In the example, 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, trigger, button, joystick, dial, and / or other suitable control mechanism (e.g., mounted to the GTAW torch 400). In some examples, the remote controller 140 is configured to detect the activation (e.g., depression) and / or movement of the movable pedal and output one or more control signals based on the degree of activation and / or amount of movement (and / or an indication thereof). 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 depress and / or move the movable pedal to different degrees to command delivery of different target levels of welding power to the GTAW torch 400, and the welding power supply 108 can interpret and / or respond to the representative signals from the remote controller 140 accordingly. In some examples, the remote controller 140 can include wireless communication circuitry that enables wireless transmission of the remote control signal (e.g., to the junction box and / or the welding 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 controller 140 itself being coupled to the junction box 600.

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

[0041] In Figure 1 the example, the fixture 114 is attached to the support platform 120 of the welding table 102 and the welding power supply 108. In some examples, the fixture 114 can be attached to the workpiece 110, some other part of the welding table 102, or some other device rather than to the support platform 120. Although shown as connected to the power supply 108 in Figure 1 the example, in some examples, the fixture 114 can alternatively be connected to the junction box 600. During live welding, the support platform 120, the workpiece(s) 110, the fixture 114, the GTAW torch 400, and / or the cable(s) connecting the fixture 114 and / or the GTAW torch 400 to the welding power supply 108 can form a closed loop through which welding output power can be delivered.

[0042] In Figure 1 the example of, the welding 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 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 the arc and / or the weld pool to provide a specific local atmosphere (e.g., shielding the arc, enhancing arc stability, limiting the formation of metal oxides, enhancing the wetting of the metal surface, altering the chemistry of the weld deposit, etc.).

[0043] In Figure 1 the example of, the welding power supply 108 further includes an operator interface 144. In Figure 1 the example of, 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 jacks configured to connect to (and / or house) one or more external memory devices (e.g., floppy disks, compact disks, digital video disks, flash drives, etc.). In some examples, instead of the operator interface 144, the operator 116 can additionally or alternatively use one or more input devices 130 of the welding table 102 and / or one or more torch inputs 416 of the GTAW torch 400.

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

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

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

[0047] During the simulation mode of the GTAW training system 100, when the operator 116 activates the remote controller 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) may be initiated. In such an example, one or more control signals indicative of the activation may be sent from the remote controller 140 to the junction box 600, which may forward the control signals to the welding table 102 (while preventing the control signals from reaching the welding power supply 108, as discussed further below). The welding table 102 may then simulate welding-type power, a welding arc, a molten weld pool, and / or other aspects of a welding operation. When the welding operation is complete, the operator 116 may deactivate the remote controller 140.

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

[0049] In Figure 1 examples, the welding table 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 can include slots and / or apertures to assist in positioning and / or orienting the workpiece(s) 110. In some examples, the workpiece(s) 110 can include extensions configured to extend into one or more slots and / or apertures to align the workpiece 110 with the one or more slots and / or apertures. In some examples, the position and / or orientation of the workpiece(s) 110, slots, and / or apertures 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 aperture and / or slot while providing user input to the GTAW training system 100 indicating that the calibration device has been inserted into the aperture and / or slot. In some examples, the GTAW torch 400 and / or the electrode attachment 500 can be used as the calibration device. In some examples, the support platform 120 can additionally or alternatively include one or more emitters configured to emit a pattern onto the support platform 120, the workpiece 110, the GTAW torch 400, and / or the operator 116. The emitter can emit a pattern in the infrared, visible, and / or ultraviolet spectrum to be detected by 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] In Figure 1 examples, the welding table 102 further includes an arm 126 that is connected to the support platform 120 and extends vertically therefrom. 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 an audio speaker.

[0051] InFigure 1 In the example of, the rack 127 is also attached to the arm 126. The rack 127 supports several input devices 130 of the welding table 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 torch 400 and / or the electrode attachment 500 may also be used as an input device 130.

[0052] In Figure 1 the example of, the welding table 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 towards the support platform 120, the operator 116, the electrode 112, and / or the GTAW torch 400. In some examples, the sensor assembly 122 may be adjustable, such as via one or more knobs and / or other adjustment mechanisms. In some examples, the sensor assembly 122 (and / or the sensors 104a) may be configured to record sensor data related to objects in the welding environment (and / or the field of view of the sensors 104) during a welding operation.

[0053] In Figure 1 the example of, the GTAW training system 100 further 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 sensors 104). As shown, in addition to the sensors 104a, the GTAW training system 100 further includes sensors 104b attached to the welding headgear 106 and sensors 104c located around the welding environment. This arrangement of the sensors 104 may enable some sensors 104 to monitor the welding environment (e.g., track the movement of objects) when other sensors 104 are blocked.

[0054] In some examples, the sensors 104 may include, for example, motion sensors, depth sensors, cameras (e.g., infrared cameras, visible spectrum cameras, high dynamic range cameras, etc.), sound sensors, light sensors, and / or other suitable sensors. In some examples, the sensor data captured by the sensors 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 table 102 to track, detect, and / or record the position, orientation, and / or movement of objects in the welding environment (e.g., the operator 116, the electrode 112, the electrode attachment 500, the GTAW torch 400, the workpiece(s) 110, etc.) during a welding operation.

[0055] In Figure 1In the example, 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 further include one or more markers built-in and / or attached to the support platform to calibrate the position and / or orientation of the support platform 120 relative to 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., light-emitting diode (LED)). In some examples, the marker 113, the torch marker 413, and / or the attachment marker 513 (and / or the spheres 520 / 530) may assist the GTAW training system 100 (e.g., via the sensors 104) in tracking the GTAW torch 400, the welding electrode 112, and / or the workpiece(s) 110, and / or determining the position and / or orientation of the GTAW torch 400, the welding electrode 112, and / or the workpiece(s) 110.

[0056] In some examples, the sensor 104 may be communicatively coupled to the training controller 200 of the welding table 102. For example, the sensor 104 may include communication circuitry 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 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. In Figure 1 the example, the training controller 200 is disposed within the cabinet 121 of the welding table 102.

[0057] In Figure 2 the example, 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 in turn coupled to and / or communicates with the GTAW torch 400, the remote controller 140, and the welding-type power supply 108. In some examples, the junction box 600 may additionally be coupled to and / or communicate with the fixture 114.

[0058] In some examples, the training controller 200 may include analog and / or discrete circuitry and / or one or more digital computing systems. In Figure 2In the example, the training controller 200 includes a memory circuit system 206, a processing circuit system 204, and an input / output (I / O) circuit system 202. In some examples, the I / O circuit system 202 may include a communication circuit system for communicating with other systems. In some examples, the communication circuit system 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 protection cable ports, cable ports, etc. In some examples, the communication circuit system 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, WirelessHD, WiGig, etc.). In some examples, the I / O circuit system 202 may additionally include circuitry for interfacing with various devices (such as, for example, sensor 104, GTAW torch 400, remote control 140, display monitor 128, power supply 108, and / or input device 130) coupled to and / or communicating with the training controller 200.

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

[0060] Figure 3 is a flowchart of an example welding training program 300 for the training controller 200. In some examples, the welding training program 300 may be implemented with machine-readable (and / or processor-executable) instructions stored in the memory circuit system 206 of the training controller 200 and / or executed by the processing circuit system 204. In Figure 3In the example, the welding training program 300 starts at block 302. At block 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 calibration on the welding table 102, the GTAW torch 400, and / or the electrode attachment 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 from the input device 130 indicating a selection of a simulation mode or a live arc mode. As another example, the welding training program 300 can set welding operations, welding training activities, settings, and / or parameters in response to receiving one or more signals from the input device 130 indicating a selection of one or more welding operations, welding training activities, settings, and / or parameters. 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 from the input device 130 indicating user login and / or user credentials.

[0061] In Figure 3 the example, the welding training program 300 continues from block 302 to block 304. At block 304, the welding training program 300 determines whether a welding session should start and / or has started. In some examples, a welding session can include one or more welding operations. In some examples, a welding session can be part of a welding training activity. In some examples, the determination at block 304 can include determining whether a welding session, a welding training activity, and / or a welding operation has been selected to start (e.g., via the input device 130, the GTAW torch 400, the remote control 140, and / or the operator interface 144). In some examples, the determination can include determining whether block 302 has been satisfactorily completed. In some examples, the determination can include determining whether the GTAW torch 400 has been activated (e.g., via the 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 block 302. If the welding training program 300 determines that the welding session should start or has started, the welding training program 300 continues to block 306.

[0062] In Figure 3In the example, at block 306, the welding training program 300 tracks objects in the nearby welding environment (e.g., the GTAW torch 400, the welding rod 112 and / or the welding rod attachment 500, the workpiece(s) 110, the welding table 102, the operator 116, etc.). In some examples, the welding training program 300 may use sensor data received from the sensor 104 (and / or the sensing device 105) to perform the tracking. For example, the sensor 104 may 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 may process the sensor data to detect, identify, and / or track objects. In some examples, the welding training program 300 may use the markers 113, the torch marker 413, and / or the attachment marker 513 (and / or the spheres 520 / 530) to detect, identify, and / or track objects.

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

[0064] In Figure 3In the example, the welding training program 300 continues from block 307 to block 308. At block 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 can 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, weave shape / amplitude / frequency, etc.), and / or other relevant parameters. In some examples, the welding training program 300 can determine the one or more parameters based on: the position and / or orientation determined at block 307; the detection, identification, and / or tracking of an object via data from the sensor 104 at block 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); the settings and / or calibrations performed at block 302; and / or other relevant information.

[0065] In Figure 3 the example, the welding training program 300 continues from block 308 to block 310. At block 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 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 block 306. If the welding training program 300 determines that the welding session has ended or should end, the welding training program 300 continues to block 312.

[0066] In Figure 3In the example of, the welding training program 300 determines one or more training results at block 312. In some examples, the training results can be determined based on the parameters at block 312 (and / or the tracking data and / or position / orientation data of blocks 306 and 307). In some examples, the training results 208 can include one or more scores, grades, ratings, sets of parameters, 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 the (multiple) welding operations, training activities, etc.). In some examples, the training results can include two or more parameters synchronized over time. In some examples, the score, grade, and / or rating can be at least partially based on a comparison of these parameters with one or more parameters from a previous welding session (and / or the (multiple) welding operations, training activities, etc.). In some examples, the previous welding session (and / or the (multiple) welding operations, training activities, etc.) and / or the associated parameters can be stored in the memory circuitry 206. In some examples, the training controller 200 can associate the training results and / or parameters with the identity of the operator 116, such as via a unique number associated with the operator 116, the name of the operator 116, and / or other identification information of the operator 116.

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

[0068] Figure 6 is a block diagram showing Figure 1 the more detailed components and connections of the junction box 600. In Figure 6 the example of, the junction box 600 includes an input device 602, an output device 604, a box sensor 606, a switch 608, and a box control circuitry 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 conveying a shielding gas). As Figure 6Depicted on the other side of the middle junction box 600, the output device 604a and the output device 604b are electrically connected to the GTAW torch 400, the output device 604c is fluidly connected to the GTAW torch 400, and the input device 602d is electrically connected to the remote controller 140. Inside the junction box 600, in Figure 6 the example, both the input device 602a and the output device 604a are electrically connected to the box control circuitry 610. The input device 602d is also depicted as being electrically connected to the box control circuitry 610. As shown, the input device 602b and the output device 604b are electrically connected to each other via the power line 612. Similarly, the input device 602c is shown as being fluidly connected to the output device 604c via the gas line 614.

[0069] In Figure 6 the example, the input device 602d is selectively connected to the output device 604d by 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 circuitry 610. In some examples, the switch 608 may couple or decouple the input device 602d and the output device 604d in response to one or more signals received from the box control circuitry 610. For example, the box control circuitry 610 may determine that the GTAW training system 100 is in the live arc mode and send one or more signals indicating a closing command to the switch 608. In response, the switch 608 may close, thereby coupling the input device 602d and the output device 604d together, allowing signals from the remote controller 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 controller 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 circuitry 610 may determine that the GTAW training system 100 is in the simulation mode and send one or more signals indicating an opening command to the switch 608. In response, the switch 608 may open, thereby decoupling the input device 602d and the output device 604d. As a result, signals from the remote controller 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 signals from the remote controller 140 for commanding the delivery of welding-type power and / or gas to the GTAW torch 400 and, in response, may never deliver power or gas to the GTAW torch 400.

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

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

[0072] In some examples, input device 602b can include a conductive physical power connection port (e.g., male plug or female socket) configured to be electrically coupled to a power cable that can be connected to welding-type power supply 108. In some examples, output device 604b can include a conductive physical power connection port (e.g., male plug or female socket) configured to be electrically coupled to a power cable that can be connected to GTAW torch 400. In some examples, input device 602b and / or output device 604b can be configured to handle higher voltage, current, and / or power than input device 602a, input device 602d, output device 604a, and / or output device 604d.

[0073] In some examples, the input device 602c can include a physical gas connection port (male or female port) configured to couple with a gas cable that can be connected to the gas supply 142 of the welding power supply 108. In some examples, the output device 604c can include a physical gas connection port (male or female port) configured to couple with a gas cable that can be connected to the GTAW torch 400. In some examples, the input device 602c and / or the output device 604c can be omitted, and / or the gas can be delivered outside the junction box 600 instead. Although depicted as separate input devices 602 in the Figure 6 example, in some examples, the output device 604d, the input device 602b, and / or the input device 602c can be combined into a single device and / or configured to connect to a single cable (e.g., a Dinse or Tweco style cable in the United States or Europe). Similarly, in some examples, the output device 604b and / or the output device 604c can be combined into a single device and / or configured to connect to a single cable (e.g., a Dinse or Tweco style cable in the United States or Europe).

[0074] In Figure 6 the example, 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 with the GTAW torch 400. As shown, the gas line 614 fluidly couples the input device 602c and the output device 604c. In Figure 6 the example, 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 line 614. In some examples, the gas flow sensor 606c can be configured to sense, detect, and / or measure the gas flow through the gas line 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, the voltage sensor 606a can be configured to sense, detect, and / or measure the voltage on the power line 612. In Figure 6In the example, 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 the voltage difference between the power line 612 and the electrical ground 616. In some examples, a second (fixture) power line (e.g., for the fixture 114) can be routed through the junction box 600, and the voltage sensor 606 can alternatively sense, detect, and / or measure the voltage difference between the GTAW torch power line 612 and the fixture power line.

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

[0077] In Figure 6In the example, 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 act as both input devices and output devices. In this 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 torch 400) and input signals (e.g., from the training controller 200 and / or the GTAW torch 400) to the cartridge control circuit system 610. For example, the cartridge control circuit system 610 can transmit the control signal received from the remote controller 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.). Since the cartridge control circuit system 610 is electrically connected to the input device 602d, the cartridge control circuit system 610 is capable of receiving control signals from the remote controller 140 regardless of whether the GTAW training system 100 is in the live arc mode or the simulation mode (and / or regardless of the corresponding state of the switch 608). Therefore, the input device 602a can act as both an input device and an output device. In this case, it can serve 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 circuit system 610 can transmit 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 circuit system 610 via the output device 604a, and the control signals indicate a certain operator selection (e.g., the live arc mode or the simulation mode) made via the torch input 416. Therefore, the output device 604a can act as both an input device and an output device. In this case, it can serve as a conduit for both input signals from the GTAW torch 400 and output signals to the GTAW torch 400.

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

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

[0080] In Figure 7 an example, the cartridge control method 700 begins at block 702, where the cartridge control circuitry 610 receives an input from the GTAW torch 400 via the output device 604a. In some examples, the input may be one or more signals sent from the GTAW torch 400 in response to an input received via the 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 circuitry 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 circuitry 610 determines the mode of the GTAW training system 100 (e.g., live arc or simulation). 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 an input from the GTAW 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 (e.g., in the case where the GTAW training system 100 is no longer in a setup / calibration phase or other appropriate phase), despite an input from the GTAW torch 400.

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

[0082] In Figure 7 the example, at block 711, method 700 processes and / or analyzes one or more control signals received from the remote controller 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 block 708 or 710 is performed. Thus, regardless of whether the GTAW training system 100 is in the live arc mode, the simulation mode, or some other mode (and / or whether switch 608 is open or closed), the welding training program 300 of the training controller 200 can use the remote control signal(s). After block 711, method 700 continues to block 712.

[0083] In Figure 7 the example, method 700 processes and / or analyzes data received from the cartridge sensor 606 at block 712, and / or sends the cartridge sensor data to the training controller 200. In some examples, the training controller 200 may use the cartridge sensor data to determine one or more parameters (e.g., at Figure 3 block 308 of Figure 3at the box 312). As shown, method 700 continues from box 712 to box 714. At box 714, method 700 sends one or more control signals to the GTAW torch 400 via the output device 604a to control the torch marker 413, the torch output 418, and / or the feedback mechanism 420. For example, the box control circuitry 610 can control the activation and / or deactivation of one or more torch markers 413 (and / or multiple sets of torch markers 413) to facilitate detection and / or tracking by the GTAW training system 100. In some examples, the box control circuitry 610 can use one or more signals received from the training controller 200 to determine how to control the torch marker 413. For example, the training controller 200 can provide one or more signals to the box control circuitry 610 indicating data captured by the sensors 104 and / or the tracking operation, and the box control circuitry 610 can control the torch marker 413 based on the one or more signals. As another example, the box control circuitry 610 can activate and / or deactivate one or more torch outputs 418 to indicate the mode of the GTAW training system 100 and / or whether the GTAW training system 100 is in a state where the mode can change. As yet another example, the box control circuitry 610 can send one or more signals indicating commands 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 method 700 is depicted as ending after box 714, in some examples, method 700 can restart at box 702 after ending.

[0084] The present disclosure describes a GTAW training system 100 that uses torch markers 413, a welding electrode attachment 500 with attachment markers 513, and a junction box 600 to facilitate training in the unique context of a gas tungsten arc welding system. Given the lack of welding expertise in the industry and the uniqueness of GTAW welding, a training system like the disclosed GTAW training system 100 plays an important role. Additionally, the ability of the GTAW training system to operate in a live arc mode and a simulation mode means that one can hone their skills in a simulated environment before performing real live welding and obtain valuable feedback for both modes.

[0085] The present method and / or system can be implemented by hardware, software, or a combination of hardware and software. The present 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 across several interconnected computing systems or cloud systems. Any kind of computing system or other device suitable for executing the methods described herein is suitable. A typical combination of hardware and software can be a general-purpose computing system with a program or other code that, when loaded and executed, controls the computing system to cause the computing system to execute the methods described herein. Another typical implementation can include a dedicated integrated circuit or chip. Some embodiments can include a non-transitory machine-readable (e.g., computer-readable) medium (e.g., a flash drive, an optical disc, a magnetic storage disk, etc.) on which one or more lines of code executable by a machine are stored, causing the machine to execute the processes described herein.

[0086] Although the present method and / or system has been described with reference to certain embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted without departing from the scope of the present method and / or system. Additionally, many modifications can 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 in a list connected by “and / or”. 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" respectively refer to structural connection and / or electrical connection, whether by attachment, adhesion, connection, combination, fastening, association, and / or otherwise secured. As used herein, the term "attach" refers to attaching, coupling, connecting, combining, fastening, associating, and / or otherwise securing. As used herein, the term "connect" refers to making an attachment, adhesion, coupling, combination, fastening, association, 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 can be configured with the hardware, executed by the hardware, and / or otherwise associated with the hardware. As used herein, for example, a particular processor and memory can constitute a first "circuit" when executing a first line or lines of code, and a second "circuit" when executing a second line or lines of code. As used herein, a circuit system is "operable" and / or "configured" to perform a function when it includes the hardware and / or code (if necessary) required to perform that function, regardless of whether the performance of the function is disabled or enabled (e.g., by user-configurable settings, factory adjustments, etc.).

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

[0092] As used herein, the term "processor" refers to processing devices, apparatuses, programs, circuits, components, systems, and subsystems, whether implemented in hardware, software embodied in a tangible medium, or both hardware and software, and whether or not it is programmable. The term "processor" as used herein includes, but is not limited to, one or more computing devices, hardwired 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 a chip, systems including discrete components and / or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. A processor can be, for example, any type of general-purpose microprocessor or microcontroller, digital signal processing (DSP) processor, application specific integrated circuit (ASIC), graphics processing unit (GPU), reduced instruction set computer (RISC) processor having an advanced RISC machine (ARM) core, and the like. A processor can 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 can 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 disc 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 can include, for example, non-transitory memory, non-transitory processor-readable media, non-transitory computer-readable media, 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 space, semiconductor memory, magnetic memory, optical memory, flash memory, flash card, compact flash card, memory card, secure digital memory card, micro card, mini card, expansion card, smart card, memory stick, multimedia card, picture card, flash device, subscriber identity module (SIM) card, hard disk drive (HDD), solid state drive (SSD), etc. The memory can be configured to store code, instructions, applications, software, firmware, and / or data, and can be disposed external to the processor, within the processor, or both external and internal to the processor.

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

[0095] As used herein, welding-type power refers to power suitable for the following: 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 gouging, and / or resistive preheating.

[0096] As used herein, a welding power supply and / or power source refers to any device that is capable of providing power to welding, cladding, brazing, plasma cutting, induction heating, laser machining (including laser welding, laser hybrid machining, and laser cladding), carbon arc cutting or gouging, 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, switched-mode power supplies, etc., as well as control circuitry and other auxiliary circuitry associated therewith.

Claims

1. A gas tungsten arc welding (GTAW) training system comprising: a GTAW welding torch comprising a first set of visual markings; an accessory configured to be attached to a welding electrode, the accessory including a second set of visual indicia; one or more sensors configured to detect the first set of visual indicia and the second set of visual indicia; as well as control circuitry in communication with the one or more sensors, the control circuitry being configured to: determining a first position of the GTAW welding torch or a first orientation of the GTAW welding torch based on detection of the first set of visual markers by the one or more sensors, and A second position of the welding electrode or a second orientation of the welding electrode is determined based on detection of the second set of visual markers by the one or more sensors.

2. The gas tungsten arc welding training system according to claim 1, wherein: The control circuitry is further configured to determine one or more torch parameters based on the first position or the first orientation of the GTAW torch and to determine one or more rod parameters based on the second position or the second orientation of the welding rod.

3. The gas tungsten arc welding training system according to claim 2, wherein: The one or more torch parameters include one or more of a working angle or a travel angle of the GTAW torch.

4. The gas tungsten arc welding training system according to claim 2, wherein: The one or more electrode parameters include one or more of a working angle, an immersion parameter, or a travel angle of the electrode.

5. The gas tungsten arc welding training system according to claim 2, wherein: The control circuit system is further configured to determine the one or more torch parameters based on the first position or the first orientation of the GTAW welding torch, and determine the one or more welding rod parameters based on the second position and the second orientation of the welding rod, wherein the one or more torch parameters include the arc length, travel speed or alignment of the GTAW welding torch, and the one or more welding rod parameters include one or more immersion parameters, one or more swing parameters, the alignment of the welding rod, the working angle of the welding rod or the travel angle of the welding rod.

6. The gas tungsten arc welding training system according to claim 2, further comprising a display screen, wherein The control circuitry is further configured to display on the display screen graphical representations of the one or more torch parameters and the one or more electrode parameters that are time synchronized with the welding parameter data.

7. The gas tungsten arc welding training system according to claim 2, wherein: The control circuitry is configured to determine a vector based on detection of the second set of visual indicia, and the control circuitry is further configured to determine the one or more electrode parameters based on the vector.

8. The gas tungsten arc welding training system according to claim 1, wherein: The accessory includes a body having a plurality of planar interconnected surfaces, the body having a through hole configured to receive the welding rod.

9. The gas tungsten arc welding training system according to claim 1, wherein: The attachment comprises two spherical markers connected together.

10. The gas tungsten arc welding training system according to claim 1, wherein: The second set of visual markers is arranged in a manner to define a rigid body.

11. A method of operating a gas tungsten arc welding (GTAW) system, the method comprising: detecting, via one or more sensors, a first set of visual markings of a GTAW welding torch; detecting, via the one or more sensors, a second set of visual indicia of an accessory attached to the welding electrode; determining, via control circuitry, a first position of the GTAW welding torch or a first orientation of the GTAW welding torch based on detection of the first set of visual markers by the one or more sensors; as well as A second position of the welding electrode or a second orientation of the welding electrode is determined based on detection of the second set of visual markers by the one or more sensors via the control circuit system.

12. The method of claim 11, further comprising: One or more torch parameters are determined via the control circuit system based on the first position or the first orientation of the GTAW torch, and one or more rod parameters are determined via the control circuit system based on the second position or the second orientation of the welding rod.

13. The method of claim 12, wherein: The one or more torch parameters include one or more of a working angle or a travel angle of the GTAW torch.

14. The method of claim 12, wherein: The one or more electrode parameters include one or more of a working angle, an immersion parameter, or a travel angle of the electrode.

15. The method of claim 12, further comprising time synchronizing the one or more torch parameters and the one or more electrode parameters with welding parameter data.

16. The method of claim 12, wherein: The one or more torch parameters are determined based on the first position and the first orientation of the GTAW welding torch, and the one or more welding rod parameters are determined based on the second position and the second orientation of the welding rod, wherein the one or more torch parameters include the arc length, travel speed or alignment of the GTAW welding torch, and the one or more welding rod parameters include one or more immersion parameters, one or more swing parameters, the alignment of the welding rod, the working angle of the welding rod or the travel angle of the welding rod.

17. The method of claim 12, further comprising displaying on a display screen a graphical representation of the one or more torch parameters and the one or more electrode parameters time-synchronized with the welding parameter data.

18. The method of claim 11, wherein: The accessory includes a body having a plurality of planar interconnected surfaces, the body having a through hole configured to receive the welding rod.

19. The method of claim 11, wherein: The attachment comprises two spherical markers connected together.

20. The method of claim 11, wherein: The one or more sensors include one or more cameras.

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