Remote Manufacturing System

Abstract

A remote manufacturing system includes a manufacturing environment including equipment used in a manufacturing process; a plurality of sensors disposed within the manufacturing environment proximate to the manufacturing equipment, each sensor configured to collect data from the manufacturing environment; at least one digitizer in communication with the sensors to receive data from the sensors and convert the data into one or more three-dimensional digital maps or point clouds; at least one processor in communication with the at least one digitizer, the processor including software for receiving and analyzing the digital maps or point clouds; and at least one manual controller in communication with the processor, the manual controller receiving operational inputs from a user, the software on the processor mathematically converting the operational inputs into corresponding operational commands that are transmitted by the processor to the manufacturing equipment, the manufacturing equipment being physically remote from the at least one controller, and executing the operational commands in real time during the manufacturing process.

Description

[Technical Field]

[0001] The inventive subject matter disclosed herein relates to industrial manufacturing and processing systems and methods, and more particularly to manufacturing or welding systems operated from a remote location, also referred to as "remote manufacturing" or "remote welding" systems.

[0002] The welding industry is currently facing a shortage of skilled welders and a lack of employment in occupations traditionally considered "manual." shortage of skilled welders, and other high-temperature work-related issues that make it difficult to find and retain experienced welders In addition, the manufacturing process is facing a variety of challenges, including increased risk and restrictions. The industry's efforts to optimize weight and space have resulted in buildings that are essentially impassable to humans. Therefore, if you have physical limitations, age, or To ensure that qualified welders can enter and remain in the workforce regardless of other barriers, including There is a continuing need for welding systems, processes, and methods that can. The prior art documents relevant to the invention of this application are as follows (including documents cited in the international phase after the international filing date and documents cited when the invention entered the national phase in other countries). (Prior art document) (Patent document) (Patent Document 1) U.S. Patent No. 6,103,994 (Patent Document 2) U.S. Patent Application Publication No. 2004 / 0217096 (Patent Document 3) U.S. Patent Application Publication No. 2018 / 0078444 Summary of the Invention

[0003] The following provides a summary of certain embodiments of the disclosed inventive subject matter. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the disclosed inventive subject matter or to delineate the scope thereof. However, it should be understood that the use of indefinite articles in the language used to describe and claim the disclosed inventive subject matter is not intended to limit the described inventive subject matter in any way. Rather, the use of "a" or "an" should be construed to mean "at least one" or "one or more."

[0004] One embodiment of the disclosed technology includes a manufacturing environment, the manufacturing environment including equipment used for or associated with a manufacturing process; at least one sensor located within the manufacturing environment proximate to the manufacturing equipment, the at least one sensor configured to collect data from the manufacturing environment; at least one digitizer in communication with the plurality of sensors to receive data from the sensors and convert the data into one or more three-dimensional digital maps; and at least one processor in communication with the at least one digitizer, the at least one processor configured to convert the data into one or more three-dimensional digital maps. and at least one manual control device in communication with the processor, the at least one manual control device receiving operational inputs from a user of the manual control device, the software on the processor mathematically converting the operational inputs into corresponding operational commands that are transmitted by the processor to the manufacturing equipment, the manufacturing equipment being physically remote from the at least one controller, and executing the operational commands in real time during the manufacturing process.

[0005] The system may further include a computer network through which the processor communicates with the manufacturing equipment. The manufacturing equipment may include welding equipment, measuring equipment, inspection equipment, remote assembly equipment, or a combination thereof. The manufacturing equipment is capable of movement with at least three degrees of freedom or at least six degrees of freedom. The at least one sensor may be an optical sensor or an acoustic sensor. The digitizer converts the data received from the sensor into a point cloud. The processor may be a computer. The at least one manual control device may be a handheld stylus, a computer mouse, or a joystick. The at least one manual control device is capable of movement with at least three degrees of freedom or at least six degrees of freedom. The at least one manual control device may be configured to provide tactile feedback to a user of the control device.

[0006] Another embodiment of the disclosed technology includes a manufacturing environment including equipment used for or associated with a manufacturing process, the manufacturing equipment moving with at least three degrees of freedom or at least six degrees of freedom; and at least one sensor disposed within the manufacturing environment proximate to the manufacturing equipment, the at least one sensor configured to collect data from the manufacturing environment. and at least one manual control device in communication with the processor, the manual control device moving with at least three degrees of freedom or at least six degrees of freedom, the at least one manual control device receiving motion inputs from a user of the manual control device, the software on the processor mathematically converting the motion inputs into corresponding motion commands that are sent by the processor to the manufacturing equipment, the manufacturing equipment being physically separate from the at least one controller and executing the motion commands in real time during the manufacturing process.

[0007] The system may further include a computer network through which the processor communicates with the manufacturing equipment. The manufacturing equipment may include welding equipment, measuring equipment, inspection equipment, remote assembly equipment, or a combination thereof. The at least one sensor may be an optical sensor or an acoustic sensor. The digitizer converts the data received from the sensor into a point cloud. The processor may be a computer. The at least one manual control device may be a handheld stylus, a computer mouse, or a joystick. The at least one manual control device may be configured to provide tactile feedback to a user of the control device.

[0008] Yet another embodiment of the disclosed technology provides a method for remotely manually controlling a manufacturing process, comprising: installing in a manufacturing environment equipment used in or associated with the manufacturing process; and disposing at least one sensor located within the manufacturing environment proximate to the manufacturing equipment, the at least one sensor configured to collect data from the manufacturing environment; connecting at least one digitizer to the sensors to receive data from the sensors and convert the data into one or more three-dimensional digital maps; and connecting at least one processor to the at least one digitizer, the at least one processor including software for receiving and analyzing the at least one three-dimensional digital maps; and connecting at least one manual control device to the processor, the at least one manual control device receiving operational inputs from a user of the manual control device, software on the processor mathematically converting the operational inputs into corresponding operational commands that are sent by the processor to the manufacturing equipment, the manufacturing equipment being physically remote from the at least one control device and executing the operational commands in real time during the manufacturing process.

[0009] The method may further include providing a computer network through which the processor communicates with the manufacturing equipment. The manufacturing equipment may include welding equipment, measuring equipment, inspection equipment, remote assembly equipment, or a combination thereof. The manufacturing equipment is capable of movement with at least three degrees of freedom or at least six degrees of freedom. The at least one sensor may be an optical sensor or an acoustic sensor. The digitizer converts the data received from the sensor into a point cloud. The processor may be a computer. The at least one manual control device may be a handheld stylus, a computer mouse, or a joystick. The at least one manual control device is capable of movement with at least three degrees of freedom or at least six degrees of freedom. The at least one manual control device may be configured to provide tactile feedback to a user of the control device.

[0010] It should be understood that all combinations of the foregoing concepts and additional concepts described in more detail below (provided that such concepts are not mutually inconsistent) are contemplated as part of the inventive subject matter disclosed herein and may be implemented to achieve the advantages as described herein. Additional features and aspects of the disclosed systems, apparatus, and methods will become apparent to those skilled in the art upon reading and understanding the following detailed description of the illustrative examples. As will be appreciated by those skilled in the art, further embodiments are possible without departing from the scope and spirit of what is disclosed herein. Accordingly, the drawings and associated description are to be regarded as illustrative and not restrictive in nature.

[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate generally one or more exemplary embodiments of the disclosed inventive subject matter and, together with the general description given above and the detailed description given below, serve to explain the principles of the disclosed subject matter, wherein: [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a block diagram of an embodiment of the disclosed remote welding system, showing the basic components of the system. [Figure 2] FIG. 2 is a flow chart of an exemplary method for using an embodiment of the disclosed remote welding system.

[0013] Examples will now be described with reference to the figures. Reference numerals are used throughout the detailed description to refer to various elements and structures. While the following detailed description contains many specific details for purposes of explanation, those skilled in the art will appreciate that many variations and modifications to the following details are within the scope of the disclosed inventive subject matter. Accordingly, the following embodiments are described without any loss of generality to, and without imposing limitations on, the claimed subject matter.

[0014] The disclosed technology includes remote manufacturing systems and methods that enable operation of equipment from one or more locations physically separated from the actual manufacturing site. The term "teleoperation" generally refers to the operation of a system or machine from a remote location and has a similar meaning to the term "telecontrol," although this term is typically used in research, academic, and technical contexts. While teleoperation is most commonly associated with robotics and mobile robots, it can be applied to any situation in which a person operates a device or machine from a remote location. In one embodiment of the disclosed technology, a system is provided that allows a worker to operate welding equipment from a remote location while retaining full control of the device. This system allows welding professionals to gain exposure and confidence in various manufacturing techniques and processes. It can also be used to direct future efforts in the application of remote manufacturing technology by enabling any person, anywhere, to actively participate in manufacturing. Various alternative implementations of the disclosed technology include measurement equipment, inspection equipment, remote assembly equipment, or a combination thereof. Remote assembly equipment can include end effectors or other mechanical devices that can be operated by a remote user.

[0015] The disclosed remote welding system allows an individual to remotely direct the welding process by controlling welding arc on, welding arc off, welding travel speed, and welding torch angle and motion, thereby enabling the individual to make various decisions regarding the welding of parts that are not within direct line of sight or hearing. Remote welding differs from remote welding in that the remote welding machine (e.g., robot, manipulator, mechanized, automated) does not execute an independent program or motion plan. A person remote from the machine controls the welding machine and makes decisions to move the machine using a handheld stylus or similar device.

[0016] The disclosed system differs from virtual reality (VR) in that the handheld stylus is a real, physical device with multiple degrees of freedom, providing encoded position information from each axis when queried, and converting the handheld device's movements into movements on a live, articulated machine (robot) with multiple degrees of freedom. The disclosed system differs from offline planning control systems in that motion control occurs in real time, with only a few seconds of delay or latency between the user's handheld stylus movements and the movements generated by the remote machine. The disclosed control system differs from traditional master-follower control systems in that the degrees of freedom of movement on the stylus do not produce the same degrees of freedom of movement on the robot, i.e., the motion outputs of the robot and the handheld stylus are not identical. Furthermore, the number of degrees of freedom present on the handheld stylus device (or other type of control device) does not necessarily match the number of degrees of freedom on the robot. In some embodiments of the disclosed technology, the control device includes three degrees of freedom and the robot includes three degrees of freedom. In other embodiments, the control device includes six degrees of freedom and the robot includes six degrees of freedom. In other embodiments, the controller includes three or more degrees of freedom and the robot includes fewer than six degrees of freedom. Many combinations of degrees of freedom are possible. The last three degrees of freedom present on the controller do not necessarily affect the first three degrees of freedom present on the controller. Thus, the robot may include only three degrees of freedom and still be useful for manufacturing purposes in accordance with the disclosed system.

[0017] Regarding the movement of a local manipulator (e.g., stylus) and a remote machine (e.g., robot) in an implementation where both the stylus (controller) and the articulated machine (robot) include six degrees of freedom, the six degrees of freedom of the robot include X, Y, Z, roll, pitch, and yaw (Rx, Ry, Rz) movements generated by six coordinated axes of the articulated robot. The six degrees of freedom of the stylus device include X, Y, and Z movements and three gimbal axes that provide an additional three degrees of freedom. The physical sizes of the stylus and the remote machine are different from each other, and the axis connection configuration on the stylus is different from the axis configuration on the remote machine. The disclosed system uses mathematical transformations to convert the six degrees of freedom of the handheld stylus into the motions of the remote articulated machine that represent typical motions (e.g., weaving) performed by a manual welder when moving a welding torch during welding. The remote welding software program completes the conversion between the two articulated motion systems and commands the remote machine to generate the desired transformation motions.

[0018] Implementations of the disclosed system, in which both the stylus (controller) and remote robot include six degrees of freedom, produce welder motions that replicate or closely approximate the physical movements or actions of a real human welder. These "welder motions" include weld travel direction, weld travel speed, weld weave width, weld weave speed, weave direction relative to the face of the weld (or position of the wire perpendicular to the joint), torch travel angle, torch work angle, and torch tip roll (with respect to the wire or TCP (Tool Center Point)).

[0019] Figure 1 is a block diagram of an embodiment showing the basic components of the disclosed remote welding system. Referring to Figure 1, an exemplary remote welding system includes the following components that, when used together, enable an operator in direct contact with a handheld stylus device to control a welding machine or other machine that performs manual movements based on and coordinates with the movements of the handheld device, even though the machine is physically remote from the operator. The embodiment includes a processor 100, control software 200, a remote machine 300, a manual control device 400, a sensor 500, and a 3D digitizer 600.

[0020] The processor 100 may be a computer or computing device including control hardware and executes an overall program for communicating with remote devices over the Internet using wired or wireless protocols. The processor 100 is connected to a manual control device 400, which may be a handheld stylus, joystick, mouse, or other electronic or computer-compatible motion control device with at least three rotational degrees of freedom. The processor 100 is connected to the Internet and uses an Internet browser or similar program to open URLs / web pages or digital media player software. In some embodiments, other open or closed computer networks are utilized.

[0021] Control software 200 runs on processor 100 and enables communication between remote machine 300, manual controller 400, and the Internet. Control software 200 performs predetermined mathematical functions to convert physical actions from manual controller 400 into movement or motion commands sent to remote machine 300. In an exemplary embodiment, control software 200 uses digitized environmental data (e.g., point clouds) provided by a three-dimensional scanning sensor 600 (e.g., laser detection and ranging (LIDAR), blue, white, or stereo scanning sensor, etc.) and mathematical transformations to translate the digital environment into real-time haptic feedback felt by the user while holding controller 400, thereby providing the user with a physical sense of the actual working environment. Control software 200 also enables the user to start or stop communication with remote machine 300, which typically includes a robot and robot controller. The robot and robot controller hardware is typically controlled by open-source or proprietary communication protocols.

[0022] Remote welding control software developed specifically for the disclosed remote welding system includes an application executable on a system user's computer, a computer co-located with the remote machine, or the robotic controller system. The software provides a user interface for the user to simultaneously operate a locally connected stylus device and the remote machine. The software connects to and controls the remote machine using a local area network (LAN), an intranet, or the Internet. The software receives input from the user through the user interface to start or end a remote welding session or process, set or change process settings or parameters, and set or change stylus device parameters. The system software provides a method or process for communicating with at least one locally connected tactile stylus device, allowing the user to directly manipulate the stylus device while querying the position of the stylus and translating the position into resulting movement of the remote machine. In another embodiment, the welding arc start / stop process is performed using buttons or other data input / output features included on the stylus device (controller).

[0023] The control device 400 may be a manually operated device such as a handheld stylus, a computer mouse, a joystick, or any other suitable device, and can be used to record various hand movements of a user. The user's physical manipulation of the control device 400 is ultimately translated by the control software 200 into physical movements of the remote machine 300. The control device 400 also provides the user with haptic feedback responses corresponding to either physical environmental objects or virtual barriers present at the remote location.

[0024] A suitable controller 400 is a commercially available tactile feedback system, a stylus device, including a software library, imported into the remote welding software program. The remote welding software program uses the stylus software library functions to query the stylus device for its current axis position. The remote welding software program uses the stylus software library functions to send commands to the stylus device to configure the tactile feedback response of the stylus device. The stylus device applies settings commanded by the remote welding software program to generate a sensory response felt by the user holding the stylus device. The commanded settings modify the power and response characteristics of servo motors to generate the sensation of touching surfaces of different densities or levels of force, mass, gravity, or velocity. The remote welding software program determines the type of response settings based on an analysis of the current position of the remote machine and the environmental data queried from the remote environmental sensors.

[0025] The resulting motions performed by the remote machine are relative to a weld position. An American Welding Society (AWS) weld joint position for a typical 1G, 2G, or 3G groove weld is selected by the user before starting welding with the remote welding system. Alternatively, all weld positions can be determined automatically by the environmental sensor data, which can determine the current weld position and joint type. The weld joint type is a parameter required by the remote welding software program to convert the translation and rotation of the stylus motion into the resulting motion of the remote machine, and a variable used to determine the weld position of the weld joint.

[0026] Sensors 500 may include cameras, microphones, digitizers, and other types of sensing devices and may employ optical systems, apparatus, and methods for determining the displacement of physical objects within the actual work environment containing remote machine 300 and the manufacturing process occurring. Sensors 500 may also employ auditory systems, apparatus, and methods for capturing sounds within the actual work environment containing remote machine 300 and the manufacturing process occurring. Sensors 500 and 600 are used to collect digitized environmental data (e.g., a point cloud) that is transmitted to and stored by processor 100. The digitized environmental data is then used to determine when, how, and what type of somatosensory response to apply to the handheld device to indicate the presence of a physical object in the work environment or the proximity of a physical object or virtual barrier. With regard to the welding process, (1) inexpensive digital cameras can be used to assist with proper line-up and weld placement, (2) specialized arc welding process cameras can be used to provide real-time weld puddle views, (3) microphones can be used to add arc sounds so that experienced welders can perform acceptable welds remotely, and (4) live streaming camera footage and audio can be used to provide low-latency real-time process data.

[0027] The three-dimensional digitizer 600 works in conjunction with the sensor 500, which measures the displacement of objects relative to itself, to provide a digitized topographical representation of the physical environment in which the manufacturing process is occurring. For example, optical-based processes such as infrared (IR), laser detection and ranging (LIDAR), blue, white, or laser vibrometer scanning systems can be used to create a point cloud or three-dimensional digital map of the remote manufacturing environment. Scanning and digitization can be completed before the manufacturing process or in real time as the manufacturing process is occurring. For welding processes, the manufacturing environment can be scanned and digitized to: (1) transmit the geometry of the weld joint to a system to enable tactile feedback on the scanned area; (2) alert the user to upcoming joint variations or obstacles in the welding path; and (3) transmit the location of the weld joint to a system to align the robot and remote manipulator to the same reference plane and field of view.

[0028] The disclosed remote welding system provides a local system user with real-time video and audio feedback of the remote environment. Video, audio, or other sensor data is encoded using an encoding software program running on a commercially available encoding hardware server or processor. The server or processor, using commercially available software, publishes the encoded video, audio, or other data stream to the Internet or LAN through a URL or web address. The published live stream uses a low-latency protocol to stream information to devices on the Internet or local area network (LAN). A user can access the live stream video over the Internet or LAN using the processor (e.g., a personal computer) and a commercially available media player application capable of reading and playing the audio or video stream on the user's personal computer.

[0029] 2 provides a flowchart of an exemplary method or steps for using an embodiment of the disclosed remote welding system. In FIG. 2, the method begins at step 1000, where a local system user remote from a welding environment initiates a local remote welding software program on a processor at step 1002, the local remote welding software program connects to a remote welding robot using an intranet connection at step 1004, remote environmental sensors connected to the welding robot transmit data to the welding robot at step 1006, a remote camera and microphone stream video and audio data to an intranet at step 1008, the local processor connects to a live streaming media software program or web browser at step 1010, the local remote welding software program connects to a local manual control device connected to the local processor at step 1012, the local system user views real-time video data from the camera at step 1014, and the local system user controls the remote welding robot at step 1016. The local remote welding software program listens to real-time audio data from a microphone that is live streamed from the welding environment, the local remote welding software program receives information from the welding robot and environmental sensors in step 1016, the local remote welding software program updates the haptic feedback response of the manual controller based on the environmental sensor data in step 1018, the local system user operates the manual controller in step 1020, the local remote welding software program converts the motion and velocity of the manual controller into a motion path for the welding robot in step 1022, the welding robot executes the motion path movement of the welding robot in response to the local system user's commands (welding parameters and functions, motion, velocity) in step 1024, and the system determines whether to stop (end) the process in step 1026 and ends the process in step 1028 or continues the process from step 1014.

[0030] The primary advantage of the disclosed system is the transfer of manual dexterity and manual motion from a handheld physical device in one location to a machine in a remote location, using wired or wireless communication to transfer motion from one device to another. Other advantages of the disclosed system include: (a) individuals with disabilities can operate machinery in remote locations without being physically present at the machine's location; (b) workers can move from the immediate vicinity of a hazardous process or environment to a safe location to perform the work; (c) using a handheld stylus device is less physically demanding and potentially less tiring than typical worker tools required to perform a specific task, thereby leading to increased production due to reduced physical fatigue; (d) highly skilled workers are not limited by geographic location, as they can work from any physical location where a communication protocol is available to transmit motion from the stylus (or other device) to the welding machine; and (e) workers in time zones around the world can work at any time, regardless of time zones or traditional work shift durations. The disclosed system can be used in the following situations: (1) manufacturing companies; (2) physically demanding manual skill level jobs; and (3) highly skilled potential workers who retain the skills necessary to complete the job but lack the physical tenacity or stamina to perform the job for extended periods of time.

[0031] All literature and similar materials, regardless of format, cited in this application, including but not limited to patents, patent applications, articles, books, treatises, and web pages, are expressly incorporated by reference in their entirety. In the event that one or more of the incorporated literature and similar materials differs from or contradicts this application, including but not limited to defined terms, term usage, described techniques, etc., this application controls.

[0032] As stated above, and as used herein, the singular forms "a," "an," and "the" refer to both the singular and the plural unless the context clearly dictates otherwise. As used herein, the term "comprising" is synonymous with "including," "containig," or "characterized by" and is inclusive or open-ended and does not exclude additional, implicit elements or method steps. Although many methods and materials similar or equivalent to those described herein can be used, certain preferred methods and materials are described herein. Unless the context dictates otherwise, the recitation of numerical ranges by endpoints includes all values ​​subsumed within that range. Furthermore, references to "one embodiment" are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, unless expressly stated to the contrary, embodiments "having" or "having" an element or elements having a particular characteristic can include additional elements, whether or not they have that characteristic.

[0033] As used throughout this specification, the terms "substantially" and "about" are used to describe and take into account small variations due to processing variations, etc. For example, these terms can refer to ±5% or less, such as ±2% or less, such as ±1% or less, such as ±0.5% or less, such as ±0.2% or less, such as ±0.1% or less, such as ±0.05% or less, and / or 0%.

[0034] Underlined and / or italicized headings and subheadings are used for convenience only, do not limit the disclosed subject matter, and should not be referenced in connection with interpreting the description of the disclosed subject matter. All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later become known to those skilled in the art are expressly incorporated herein by reference and are intended to be encompassed by the disclosed subject matter. Furthermore, nothing disclosed herein is intended to be generic, regardless of whether such disclosure is explicitly set forth in the description above.

[0035] There may be many alternative ways of implementing the disclosed inventive subject matter. The various functions and elements described herein may be divided differently than illustrated without departing from the scope of the disclosed inventive subject matter. The general principles defined herein may be applied to other embodiments. Different numbers of given modules or units may be employed, different types or varieties of given modules or units may be employed, given modules or units may be added, or given modules or units may be omitted.

[0036] In the context of the present disclosure, the term "plurality" refers to two or more than two. Unless otherwise clearly defined, the orientation or positional relationship indicated by terms such as "upper" and "lower" is based on the orientation or positional relationship shown in the figures solely for the purpose of facilitating and simplifying the description of the present invention. It does not indicate or imply that the referenced devices or elements must be oriented, configured, or operated in a particular orientation, and therefore should not be construed as limiting the present invention. Terms such as "connected," "mounted," and "fixed" should be understood broadly. For example, "connected" may refer to a fixed connection, a detachable connection, or an integral connection, a direct connection, or an indirect connection via an intermediate medium. Those skilled in the art will understand the specific meaning of the above terms in the present invention depending on the specific circumstances.

[0037] It should be understood that all combinations of the foregoing concepts and additional concepts discussed in more detail herein (provided such concepts are not mutually inconsistent) are contemplated as part of the disclosed inventive subject matter. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as part of the inventive subject matter disclosed herein. The disclosed inventive subject matter has been illustrated by description of exemplary embodiments, and while the exemplary embodiments have been described in certain details, it is not intended to limit, or in any way limit, the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. Accordingly, the disclosed inventive subject matter, in its broader aspects, is not limited to any of the specific details, representative apparatus and methods, and / or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept.

Claims

1. 1. A system for manually and remotely controlling a manufacturing process, comprising: (a) a manufacturing environment, the manufacturing environment including manufacturing equipment used for or associated with a manufacturing process, the manufacturing equipment moving with a predetermined number of degrees of freedom; (b) at least one sensor positioned within the manufacturing environment proximate to a manufacturing device, the at least one sensor configured to collect data from the manufacturing environment; and (c) at least one digitizer in communication with the plurality of sensors to receive data from the sensors and convert said data into one or more three-dimensional digital maps; (d) at least one processor in communication with the at least one digitizer, the at least one processor including software for receiving and analyzing the at least one three-dimensional digital map; (e) at least one manual control device in communication with the at least one processor, the at least one manual control device moving with a predetermined number of degrees of freedom, the at least one manual control device receiving operational inputs from a user of the at least one manual control device, the software on the at least one processor mathematically converting the operational inputs into corresponding operational commands that are sent by the processor to the manufacturing equipment, the manufacturing equipment being physically separate from the at least one manual control device executing the operational commands in real time during the manufacturing process to generate operational outputs, the operational outputs of the manufacturing equipment differing from the operational inputs of the at least one manual control device, and the predetermined number of degrees of freedom of the manufacturing equipment differing from the predetermined number of degrees of freedom of the at least one manual control device; A system having:

2. 10. The system of claim 1 further comprising: The system further comprises a computer network in communication with the at least one processor and the manufacturing device.

3. 10. The system of claim 1, wherein the manufacturing equipment comprises welding equipment, measurement equipment, inspection equipment, remote assembly equipment, or a combination thereof.

4. 2. The system of claim 1, wherein the predetermined number of degrees of freedom of the manufacturing device includes at least three degrees of freedom.

5. 2. The system of claim 1, wherein the predetermined number of degrees of freedom of the manufacturing device includes at least six degrees of freedom.

6. The system of claim 1 , wherein the at least one sensor is an optical sensor or an acoustic sensor.

7. The system of claim 1 , wherein the digitizer converts the data received from the sensor into a point cloud.

8. 10. The system of claim 1, wherein the at least one processor is a computer.

9. 10. The system of claim 1, wherein the at least one manual control device is a hand-held stylus, a computer mouse, or a joystick.

10. 2. The system of claim 1, wherein the predetermined number of degrees of freedom of the at least one manual control device comprises at least three degrees of freedom.

11. 2. The system of claim 1, wherein the predetermined number of degrees of freedom of the at least one manual control device comprises at least six degrees of freedom.

12. The system of claim 1 , wherein the at least one manual control device is configured to provide tactile feedback to the user of the control device.

13. A system for manually and remotely controlling a welding process, comprising: (a) a welding environment, the welding environment including a welding device used for or associated with a welding process, the welding environment having movement with at least six degrees of freedom; (b) at least one sensor disposed in the welding environment proximate the welding device, the at least one sensor configured to collect data from the welding environment; and (c) at least one digitizer in communication with the plurality of sensors to receive data from the sensors and convert said data into one or more three-dimensional digital maps; (d) at least one processor in communication with the at least one digitizer, the at least one processor including software for receiving and analyzing the at least one three-dimensional digital map; (e) at least one manual control device in communication with the at least one processor, the at least one manual control device moving with at least six degrees of freedom, the at least one manual control device receiving motion inputs from a user of the at least one manual control device, the software on the at least one processor mathematically converting the motion inputs into corresponding motion commands that are sent by the at least one processor to the welding device, the welding device being physically separate from the at least one manual control device, executing the motion commands in real time during the welding process to generate motion outputs, the motion outputs of the welding device differing from the motion inputs of the at least one manual control device, and the motion outputs replicating the physical movements and actions of an actual human welder. A system having:

14. 14. The system of claim 13, further comprising: The system includes a computer network in communication with the at least one processor and the welding device.

15. 14. The system of claim 13, wherein the at least one sensor is an optical sensor or an acoustic sensor.

16. 14. The system of claim 13, wherein the digitizer converts the data received from the sensor into a point cloud.

17. 14. The system of claim 13, wherein the at least one processor is a computer.

18. 14. The system of claim 13, wherein the at least one manual control device is a hand-held stylus, a computer mouse, or a joystick.

19. 14. The system of claim 13, wherein the at least one manual control device is configured to provide tactile feedback to the user of the control device.

20. 1. A method for manually and remotely controlling a manufacturing process, comprising: (a) installing manufacturing equipment used in or associated with a manufacturing process in a manufacturing environment; (b) disposing at least one sensor in the manufacturing environment proximate to a manufacturing device, the at least one sensor configured to collect data from the manufacturing environment; (c) connecting at least one digitizer to the plurality of sensors for receiving data from the sensors and converting said data into one or more three-dimensional digital maps; (d) connecting at least one processor to the at least one digitizer, the at least one processor including software for receiving and analyzing the at least one three-dimensional digital map; (e) connecting at least one manual control device to the at least one processor, wherein the at least one manual control device receives operational inputs from a user of the manual control device, the software on the at least one processor mathematically converts the operational inputs into corresponding operational commands that are sent by the at least one processor to the manufacturing equipment, and the manufacturing equipment, physically separate from the at least one manual control device, executes the operational commands in real time during the manufacturing process to generate operational outputs, the operational outputs of the manufacturing equipment being different from the operational inputs of the at least one manual control device; A method comprising:

21. 21. The method of claim 20, further comprising: The method, wherein the at least one processor has a computer network in communication with the manufacturing device.

22. 21. The method of claim 20, wherein the manufacturing equipment comprises welding equipment, measurement equipment, inspection equipment, remote assembly equipment, or a combination thereof.

23. 21. The method of claim 20, wherein the manufacturing device moves in at least three degrees of freedom.

24. 21. The method of claim 20, wherein the manufacturing device moves in at least six degrees of freedom.

25. 21. The method of claim 20, wherein the sensor of the plurality of sensors is an optical sensor, an auditory sensor, or a combination thereof.

26. 21. The method of claim 20, wherein the digitizer converts the data received from the sensor into a point cloud.

27. 21. The method of claim 20, wherein the at least one processor is a computer.

28. 21. The method of claim 20, wherein the at least one manual control device is a hand-held stylus, a computer mouse, or a joystick.

29. 21. The method of claim 20, wherein the at least one manual control device moves in at least three degrees of freedom.

30. 21. The method of claim 20, wherein the at least one manual control device moves in at least six degrees of freedom.

31. 21. The method of claim 20, wherein the at least one manual control device is configured to provide tactile feedback to the user of the control device.

32. 21. The method of claim 20, wherein the motion commands executed by the manufacturing device include weld travel direction, weld travel speed, weld weave width, weld weave speed, weave direction relative to the face of the weld, torch travel angle, torch work angle, and torch tip roll.

Images