Welding torch assemblies with dynamic vision systems

Abstract

The present disclosure provides an apparatus comprising a mounting assembly configured to engage an upper portion of a welding torch, the welding torch having a welding tip at a lower end thereof, and a camera assembly operably connected to an actuator mounted on the mounting assembly, the actuator configured to move the camera assembly to capture real time images of the welding tip and a weld pool during a welding operation from different angles.

Description

WELDING TORCH ASSEMBLIES WITH DYNAMIC VISION SYSTEMSCross-Reference to Related Application

[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 650,359 filed on May 21 , 2024, which is hereby incorporated herein by reference in its entirety.Technical Field

[0002] The present disclosure relates to robotic welding systems.Background

[0003] Various types of welding systems utilize cameras and other sensors to control and / or monitor robotic welding operations. Many existing vision-based solutions used for monitoring operations of robotic welding systems are not suitable for use in situations where there is limited clearance around the welding torch.

[0004] Examples of prior art vision-based systems for use in welding operations include Korean patent No. KR1020050068079, Chinese utility models No.CN205614171 and No. CN213560726, United States Patent No. 7715946, and PCT Publication No. WO 2024 / 108305.

[0005] The inventors have determined a need for improved apparatus and methods for capturing images (both still images and videos) of welding operations.Summary

[0006] One aspect of the present disclosure provides an apparatus comprising a mounting assembly configured to engage an upper portion of a welding torch, the welding torch having a welding tip at a lower end thereof, and a camera assembly operably connected to an actuator mounted on the mounting assembly, the actuator configured to move the camera assembly to capture real time images of the welding tip and a weld pool during a welding operation from different angles.

[0007] In another aspect of the present disclosure, an apparatus is provided comprising a mounting assembly configured to engage with a welding torch, the welding torch comprising a welding tip, and, a camera assembly connected to the mountingassembly. The camera assembly comprising, one or more primary cameras directed at the welding tip and / or weld pool, and, one or more additional cameras directed at a weld path adjacent to the welding tip.

[0008] In a further aspect of the present disclosure, a method for controlling an active welding area during welding operations is provided. The method comprising, directing a welding operation, the welding operation comprising guiding a tip of a weld torch along a path to form a weld seam, capturing real time images of the tip of the weld torch during the welding operations, capturing pre-weld images of the path ahead of the tip of the weld torch, and, controlling the weld torch based on the pre-weld images of the path ahead of the tip of the weld torch and / or the real-time images of the tip of the weld torch.

[0009] In some embodiments, the camera assembly is operably connected to an actuator mounted on the mounting assembly. The actuator may be configured to move the camera assembly to capture real time images of the welding tip and / or the weld pool on the primary camera, and images of the weld path on the one or more additional cameras, from different angles.

[0010] In some embodiments, the actuator comprises a rotary actuator having an axis of rotation aligned with a longitudinal axis of a lower portion of the welding torch, and the camera assembly is connected to the actuator by a camera arm connected to the rotary actuator.

[0011] In some embodiments, the lower portion of the welding torch is oriented at a gooseneck angle with respect to the upper portion of the welding torch, and the mounting assembly comprises a support plate mounted on the upper portion of the welding torch and comprising a bent portion oriented at the gooseneck angle for supporting the rotary actuator.

[0012] In some embodiments, the mounting assembly comprises a robotic arm connector for coupling the apparatus to a robotic arm.

[0013] In some embodiments, the lower portion of the welding torch is aligned with the upper portion of the welding torch, the rotary actuator has an aperture therein configured to fit around the upper portion of the welding torch, and the mountingassembly comprises a clamp for holding the rotary actuator in place on the upper portion of the welding torch.

[0014] In some embodiments, the camera assembly comprises one or more primary cameras configured to capture images of an area around the welding tip during the welding operation showing the size and shape of a weld pool and the position of the weld pool relative to a weld seam.

[0015] In some embodiments, the camera assembly comprises one or more additional cameras positioned to collectively capture images in front of the welding tip during the welding operation.

[0016] In some embodiments, the camera assembly comprises an integrated illumination system.

[0017] In some embodiments, the camera assembly comprises one or more additional sensors for sensing at least one of distance, heat, or sound.

[0018] Further aspects of the present disclosure and details of example embodiments are set forth below.Drawings

[0019] The following figures set forth embodiments in which like reference numerals denote like parts. Embodiments are illustrated by way of example and not by way of limitation in the accompanying figures.

[0020] Figure 1 shows an apparatus for providing dynamic vision for a welding torch of a robotic welding system according to one aspect of the present disclosure.

[0021] Figure 1A shows the apparatus of Figure 1 mounted on a robotic arm.

[0022] Figures 1 B and 1 C show the mounting structure of Figure 1 with the camera assembly oriented to capture images of the welding operation from different directions.

[0023] Figure 1 D is a top view of the apparatus of Figure 1 .

[0024] Figure 1 E is a schematic view illustrating angular relationships of the apparatus of Figure 1.

[0025] Figure 2 shows an apparatus for providing dynamic vision for a welding torch of a robotic welding system according to another aspect of the present disclosure.

[0026] Figures 2A and 2B show the mounting structure of Figure 2 with the camera assembly oriented to capture images of the welding operation from different directions.

[0027] Figure 3 shows an apparatus for providing dynamic vision for a welding torch of a robotic welding system according to another aspect of the present disclosure.

[0028] Figure 4A illustrates how vision systems for robotic welding systems can have difficulty imaging areas of welding seams near walls or other barriers.

[0029] Figure 4B illustrates how the apparatus of Figure 3 can be utilized for imaging areas of welding seams near walls or other barriers.

[0030] Figure 5 shows an apparatus for providing dynamic vision for a welding torch of a robotic welding system according to another aspect of the present disclosure.

[0031] Figure 5A shows the apparatus of Figure 5 mounted on a robotic arm.Detailed Description

[0032] The following describes example welding torch assemblies equipped with dynamic camera systems configured to capture images (both still images and videos) of an active welding area at a lower end of the welding torch from a variety of different angles. Some embodiments comprise a mounting structure for connecting to a welding torch with a camera assembly coupled thereto via an actuator, such that the position of the camera assembly with respect to the welding torch can be dynamically varied.Some embodiments of the present disclosure can be used with many different types of existing welding torches and robotic arms. As used herein, the term “robotic arm” is used to refer to all types of mechanized manipulators. Images from the camera system are provided to an image processing system, such as for example the NovEye™ system from Novarc Technologies Inc., for controlling operation of the welding torch and motions of the robotic arm. Examples of how images from cameras positioned to capture images of a welding operation are disclosed, for example, in PCT Publications No. W02019153090 and No. WO2022126274 by Novarc Technologies Inc., which are hereby incorporated by reference herein. The welding torch assemblies and mounting structures disclosed herein with dynamic vision systems can be mounted to all types of welding robots and mechanized arms.

[0033] For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practiced without these details. In other instances, well- known methods, procedures, and components are not described in detail to avoid obscuring the examples described. The description is not to be considered as limited to the scope of the examples described herein.

[0034] Figure 1 shows an example apparatus 100 for providing dynamic vision for a welding torch mounted on a robotic arm according to one embodiment of the present disclosure. The apparatus 100 comprises a mounting assembly 102 having a bracket configured to securely hold a welding torch T, with an actuator 110 mounted thereon which is connected to dynamically move a camera assembly 120 in real time during robotic welding operations as described further below.

[0035] In the Figure 1 example, the mounting assembly 102 has an arm connector 104 thereon for connecting the mounting assembly 102 to the end of a robotic arm. In some embodiments, the arm connector 104 may comprise a mounting flange with four bolts and a locator pin (not shown) for connection to some types of robotic arms, although the configuration of the arm connector 104 will depend on the configuration and the brand of the robotic arm. Figure 1A shows the apparatus 100 of Figure 1 mounted on an example six-axis robotic arm, but it is to be understood that the apparatus 100 could be mounted on any type of robotic manipulator.

[0036] The mounting assembly 102 has an actuator 110 mounted thereon which is operatively connected to a camera assembly 120, such that the actuator 110 can be controlled to dynamically adjust the position of the camera assembly 120 with respect to the welding torch during welding operations as a weld seam is being formed. The images from the camera assembly 120 are provided to an image processing system for seam tracking, distance control, and / or control of welding parameters of the welding operation.

[0037] The camera assembly 120 comprises one or more cameras oriented to capture images of the weld seam as it is formed. As used herein, the term “camera” is used to refer to an image sensor and any associated optical elements (e.g. a CCD orCMOS sensor and a lens), but not necessarily any associated control or processing circuitry. For example, in some embodiments, the camera assembly 120 consists essentially of a single image sensor and any associated lens(es) in order to minimize the mass of the camera assembly 120, with signal processing components located remotely (e.g. mounted on a supporting structure for a robotic arm, and connected to the camera assembly by one or more cables). In other embodiments, certain signal processing components may be housed within the camera assembly 120. In the illustrated example, the camera assembly 120 comprises a housing for protecting the internal components thereof, with an opening for capturing images, and one or more cable ports 122 for connecting to an image processing system.

[0038] In some embodiments, the camera assembly 120 comprises two or more cameras configured to capture real-time images of the weld pool from different angles, which are provided to the image processing system for generating a three dimensional view showing the size and shape of a weld pool during a welding operation and the position of the weld pool relative to a weld seam.

[0039] In the Figure 1 example, the mounting assembly 102 comprises a clamp 106 for engaging a welding torch T, and a support plate 107 extending laterally from the clamp 106 and having an aperture therethrough configured to receive an upper portion T-U of the welding torch T. The support plate 107 has a bent portion 108 at an end thereof which is configured to support a rotary actuator 110 having an axis of rotation aligned with a lower portion T-L of the welding torch T, and a camera arm 112 which supports the camera assembly 120 is connected to the actuator 110. As best seen in Figures 1 B, 1 C and 1 D, a portion of the camera arm 112 extends outwardly from the actuator 110 along a plane that is offset from the axis of rotation of the actuator 110, such that the arm 112 is rotatable through an arc of about 350 degrees, as discussed below.

[0040] In the Figure 1 example, the actuator 110 comprises a direct-drive motor (such as, for example, a SINADRIVES™ rotary table) mounted on the underside of the bent portion 108, and the camera arm 112 is connected directly to the actuator 110. In other embodiments, the actuator may comprise a different type of motor, and the camera arm 112 may be connected to the actuator via one or more reducing gears.

[0041] The camera arm 112 is configured to orient the optical axis of the camera assembly 120 at a desired “vertical” angle (e.g. the angle with respect to the longitudinal axis of the tip of the welding torch, for example about 40 degrees in some embodiments) to the tip of the welding torch T at the bottom of the lower portion T-L, to capture images, including real time images, of welding operations. The camera arm 112 is configured to maintain this vertical angle between the camera assembly and the welding tip as it is rotated by the actuator 110 to capture images from different “horizontal” angles (e.g. the angle around the longitudinal axis of the tip of the torch). For example, in some embodiments, the camera arm 112 is configured to be rotatable through angles with respect to the longitudinal axis of the welding tip in a range from zero degrees to about 350 degrees (depending on the thickness of the upper portion T- U of the torch T), with zero degrees being the position shown in Figure 1 and Figure 1 D, which shows the apparatus 100 and torch T from above, and illustrates how the arm 112 is adjacent to the torch T when in the zero degree position. In some embodiments, the interface between the camera arm 112 and the actuator 110 may comprise a plurality of detents, or other similar features, such that the camera arm 112 “clicks” into position at certain predetermined orientations (e.g. every 5 degrees, every 10 degrees, every 15 degrees, etc.).

[0042] In order to obtain a good image of the seam being welded, including the weld pool and the gap between the work pieces, the camera assembly 120 should ideally be aligned with the seam and oriented to view the welding arc from the “front” of the welding operation (i.e. from the direction in which the torch T is moving). For example, in Figure 1 , torch T would be moving to the right (assuming stationary workpieces) along the seam, and the camera assembly 120 is aligned with the seam. Depending on the configuration of the seam to be welded and the workpieces, the torch T will sometimes need to change directions. In some circumstances, and if space permits, the camera assembly 120 could remain in the position shown in Figure 1 , and the robotic arm could be controlled to orient the torch T with the bend or “gooseneck” pointed along the seam in the direction of welding. However, in some situations (e.g. to avoid collisions, or to simplify movements of the robotic arm), it may be desirable to move the torch T in a different direction in relation to the direction of the gooseneckbend, in which case apparatus 100 is configured to move the camera assembly 120 to maintain a desired field of view from along the seam in front of the weld pool as the torch moves relative to the workpiece(s). For example, Figure 1 B shows the camera arm 112 at about a 90 degree angle (which may, for example, be utilized when the torch is moving to the “left” with reference to the direction of the gooseneck bend), and Figure 1 C shows the camera arm 112 at about a 180 degree angle (which may, for example, be utilized when the torch is moving “backwards” with reference to the direction of the gooseneck bend). In some embodiments, the actuator 110 receives control signals from a controller of the robotic arm, or another controller acting in coordination therewith, to adjust the position of the camera assembly 120 based on the path to be taken by the torch along the seam. In some embodiments, the actuator is controlled to minimize vibration or other unwanted motion of the torch, for example by controlling ramping of speed of rotation of the camera arm 112.

[0043] In the Figure 1 example, the apparatus 100 is configured for use with an angled or “gooseneck” welding torch T, with a bend configured such that the upper portion T-U is at an angle of 40 degrees relative to the lower portion T-L where the welding tip is located. As such, the bent portion 108 of the support plate 107 is also at an angle of 40 degrees, as illustrated in Figure 1 E, such that the rotational axis of the actuator 110 is aligned with the longitudinal axis of the lower portion T-L of the torch T. However, it is to be understood that the apparatus according to the present disclosure can be configured for holding other types of welding torches by adjusting the angles of the actuator, camera arm and / or camera assembly. For example, some embodiments provide apparatus configured for use with any of a variety of a gooseneck-type welding torches having a bend angle ranging from between about 20 degrees to about 60 degrees. Figure 2 shows an example apparatus configured for use with a smaller torch having less of a bend angle. Apparatuses according to various embodiments of the present disclosure may also be adapted for use with a straight welding torch, as shown for example in Figure 5 and discussed below.

[0044] Figure 2 shows an example apparatus 200 for use with a welding torch T’ that is smaller than torch T of Figure 1 , and the gooseneck is bent at an angle of less than 40 degrees (e.g. about 20 degrees in the illustrated example). The apparatus 200of Figure 2 is similar in some respects to apparatus 100 of Figure 1 , in that apparatus 200 comprises a mounting assembly 202 comprising a support plate 207 with an aperture for receiving the upper portion T’-ll of torch T’, and a bent portion 208 for supporting an actuator 210 such that the axis of rotation of the actuator 210 is aligned with the lower portion T’-L of torch T’. In the Figure 2 embodiment, the actuator 210 comprises a small electric motor mounted on top of the bent portion, and the camera arm 212 is coupled to the actuator 210 through reducing gears 211. The camera is operable to move the camera assembly 220 through a range of angles between zero and about 340 degrees (depending on the thickness of the upper portion T’-ll of the torch T’). Figure 2A shows apparatus 200 with the camera arm 212 at about a 100 degree angle, and Figure 2B shows apparatus 200 with the camera arm 212 at about a 180 degree angle.

[0045] Figure 3 shows an example apparatus 300 for providing dynamic vision for a welding torch mounted on a robotic arm according to another embodiment of the present disclosure. The apparatus 300 is substantially the same as apparatus 100 of Figure 1 , with the exception that the camera assembly 320 of apparatus 300 comprises a pair of additional cameras 330, 332 oriented to provide images from overlapping fields of view in front of or adjacent to the welding operation in order to generate three dimensional views of the workpiece edges and of the gap to be welded. In an example, additional cameras 330, 332 provide images of the path along which the torch tip will travel under control of a robotic welding system while the primary camera(s) of camera assembly 320 provide images of the torch tip and surrounding area. The Figure 3 example provides two additional cameras in addition to the primary camera(s) on the camera assembly 320. In other examples, one additional camera or two or more additional cameras may be used to provide images of the path ahead of and / or adjacent to the torch tip in a welding operation. Such views / images may be stored in memory and used to control operation of the robotic welding system in areas where it is difficult or impossible to obtain real time views of the weld pool from appropriate angles. For example, Figure 4A shows an example welding scenario wherein a robotic welding system equipped with a dynamic vision apparatus similar to apparatus 200 of Figure 2 is welding a seam on the inside of a box, vessel, or other container, and the cameraassembly is prevented from capturing live images of the welding operation from the front as the torch approaches the corner. The camera assembly can be rotated to capture live images of the welding operation from the side by rotating the camera arm to a different angle, as discussed above, however such images may not reveal details of the workpiece edges. Figure 4B shows the apparatus 300 of Figure 3 being utilized in the same scenario, wherein the additional cameras 330 and 332 capture images of a weld path, for example, images of the workpiece edges, and the gap therebetween, for controlling operation of the welding torch during the period where the primary camera(s) of the camera assembly 320 can’t provide real time images of the weld pool from the front of the welding operation. In an example, the pre-weld images taken by the additional cameras on the camera assembly may be used to control the torch motion and the welding parameters as the torch nears an area to be welded that would otherwise be difficult or impossible to capture in real time with the primary camera. In another example, the additional cameras may be used to provide images of the welding operation after the welding process, for example, images of the weld seam, as the torch tip moves away from the edge or corner after a welding operation.

[0046] Figure 5 shows an example apparatus 500 for providing dynamic vision for a straight welding torch T” according to another aspect of the present disclosure. Apparatus 500 comprises an actuator 510 having an annular shape, with an aperture therein configured to receive the upper portion T”-U of the welding torch T”, and an axis of rotation which is thereby aligned with the lower portion T”-L of the welding torch T”. For example, the actuator 510 may comprise a direct-drive motor with a rotatable ring on the bottom thereof. A camera arm 512 is connected to the actuator 510 and supports a camera assembly 520 at a desired orientation to the welding tip, and is rotatable to capture the welding operation from different angles as described above in relation to the other example embodiments. In some embodiments, the apparatus 500 comprises a mounting assembly in the form of a clamp configured to hold the rotary actuator in place on the upper portion T”-U of the welding torch T”. The upper portion T”-U of the welding torch T” may also have a robotic arm connector for connecting to a robotic arm or other manipulator. Figure 5A shows the apparatus of Figure 5 mountedon an example six-axis robotic arm, but it is to be understood that the apparatus 500 could be mounted on any type of robotic manipulator.

[0047] In a further aspect of the present disclosure, a method is provided for controlling an active weld area, including by capturing both still and video images. The method may be used with any one or more of the implementations of the embodiments described above with reference to Figures 1-5. The method for controlling the active welding area comprises simultaneously capturing real time images on one or more primary cameras during a welding operation with respect to the welding torch tip and the surrounding weld pool, and capturing further still images and videos using additional cameras directed at the path ahead of the torch tip that would otherwise be inaccessible by the primary real-time cameras. The additional cameras may capture still images and videos of the gap between workpieces, the weld pool and even the welded seam after operations in corner cases, edges and other areas that have an obstructed view when the welding torch is acting on those areas. The welding operation may then be controlled, for example by controlling the motion of the weld torch based on the realtime images of the active welding area and the pre-weld images of the upcoming welding area.

[0048] In some implementations of the embodiments described above with reference to Figures 1-5, the camera assembly 120 / 220 / 320 / 520 comprises an integrated illumination system including one or more light emitting elements arranged around a lens of the at least one camera. In some implementations, the apparatus 100 / 200 / 300 / 500 of the embodiments described above with reference to Figures 1-5 is configured for connection to a source of compressed air or other cooling fluid for directing cooling fluid towards the camera(s) of the camera assembly 120 / 220 / 320 / 520. For example, the area near the welding operation may be very hot and may interfere with the proper operation of the camera(s) without adequate cooling. The cooling fluid may also be used for keeping the camera(s) clean and clear of smoke, weld spatter, dust, or other debris. For example, in some embodiments, an air blade or similar air direction assembly is coupled to the apparatus 100 / 200 / 300 / 500 and configured to direct forced air towards camera(s) for cooling and / or cleaning thereof. In some implementations of the embodiments described above with reference to Figures 1-5, thecamera assembly 120 / 220 / 320 / 520 comprises one or more additional sensors, such as for example laser sensors, heat sensors, pressure sensors, microphones or other sensors. In some embodiments all of the cameras and other sensors are connected to an industrial PC running an artificial intelligence (Al) system that adaptively controls the welding operation based on the image data and other sensor data. For example, the Al system may use both the real-time images of the torch tip and / or the area around the torch tip as well as images of the weld path ahead of and / or adjacent to the torch tip to efficiently guide the torch tip along the path to form a weld seam in even very small, tight or otherwise obstructed spaces.

[0049] As one skilled in the art will appreciate in light of the above disclosure, by providing one or more cameras configured to capture real time images of a welding operation, apparatus according to some embodiments of the present disclosure facilitate real-time and adaptive control of welding. The camera visualizes the real-time instance of the weld pool (or “welding puddle”), weldment geometry under the arc, the torch, wire, tack welds, root opening, high-low, gap, and other visual parameters that are important for welders. Further, additional cameras may be used to capture pre-weld or post-weld details including those similar to images captured in real-time as described above.

[0050] In embodiments with at least two cameras (or a single camera configured with optics for capturing images from different angles), including, for example, embodiments comprising one or more primary cameras and / or in embodiments comprising one or more additional cameras, apparatuses according to various embodiments of the present disclosure allow for capture of stereo vision images with depth information, and removes the sensitivity of the cameras to the tilt in the welding direction. The depth information provides the ability to generate three dimensional views of the welding features that significantly improves the visual cognition for real-time adaptive control of welding.

[0051] Also, in certain preferred embodiments of the present disclosure (regardless of the number and configuration of cameras), the apparatus is configured to generate time-stamped images of welding operations to facilitate pre- and post-weld inspection in addition to the welding control.

[0052] The embodiments of the systems and methods described herein may be implemented in a combination of both hardware and software. These embodiments may be implemented on programmable computers, each computer including at least one processor, a data storage system (including volatile memory or non-volatile memory or other data storage elements or a combination thereof), and at least one communication interface. For example, the programmable computers may be a server, network appliance, on-board controllers of a connected or autonomous vehicle, set-top box, embedded device, computer expansion module, personal computer, laptop, personal data assistant, cloud computing system or mobile device. A cloud computing system is operable to deliver computing service through shared resources, software and data over a network.

[0053] Program code is applied to input data to perform the functions described herein and to generate output information. The output information is applied to one or more output devices. In some embodiments, the communication interface may be a network communication interface. In embodiments in which elements may be combined, the communication interface may be a software communication interface, such as those for inter-process communication. In still other embodiments, there may be a combination of communication interfaces implemented as hardware, software, and combination thereof.

[0054] Each program may be implemented in a high level procedural or object oriented programming or scripting language, or both, to communicate with a computer system. However, alternatively the programs may be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language. Each such computer program may be stored on a storage media or a device (e.g. ROM or magnetic diskette), readable by a general or special purpose programmable computer, for configuring and operating the computer when the storage media or device is read by the computer to perform the procedures described herein. Embodiments of the system may also be considered to be implemented as a non- transitory computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein.

[0055] Furthermore, the system, processes and methods of the described embodiments are capable of being distributed in a computer program product including a physical non-transitory computer readable medium that bears computer usable instructions for one or more processors. The medium may be provided in various forms, including one or more diskettes, compact disks, tapes, chips, magnetic and electronic storage media, and the like. The computer useable instructions may also be in various forms, including compiled and non-compiled code.

[0056] Embodiments described herein may relate to various types of computing applications, such as image processing and generation applications, computing resource related applications, speech recognition applications, video processing applications, semiconductor fabrication, and so on. By way of illustrative example embodiments may be described herein in relation to image-related applications.

[0057] It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Furthermore, this description is not to be considered as limiting the scope of the embodiments described herein in any way, but rather as merely describing implementation of the various example embodiments described herein.

[0058] The description provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, and / or D, even if not explicitly disclosed.

[0059] As will be apparent to those skilled in the art in light of the foregoing disclosure, many alterations and modifications are possible to the methods and systems described herein. While a number of exemplary aspects and embodiments have beendiscussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as may reasonably be inferred by one skilled in the art. The scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the foregoing disclosure.

[0060] The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive.

Claims

Claims1 . An apparatus comprising: a mounting assembly configured to engage an upper portion of a welding torch, the welding torch having a welding tip at a lower end thereof; and, a camera assembly operably connected to an actuator mounted on the mounting assembly, the actuator configured to move the camera assembly to capture real time images of the welding tip and a weld pool during a welding operation from different angles.

2. The apparatus of claim 1 wherein the actuator comprises a rotary actuator having an axis of rotation aligned with a longitudinal axis of a lower portion of the welding torch, and the camera assembly is connected to the actuator by a camera arm connected to the rotary actuator.

3. The apparatus of claim 2 wherein the lower portion of the welding torch is oriented at a gooseneck angle with respect to the upper portion of the welding torch, and the mounting assembly comprises a support plate mounted on the upper portion of the welding torch and comprising a bent portion oriented at the gooseneck angle for supporting the rotary actuator.

4. The apparatus of any one of claims 1 to 3 wherein the mounting assembly comprises a robotic arm connector for coupling the apparatus to a robotic arm.

5. The apparatus of claim 2 wherein the lower portion of the welding torch is aligned with the upper portion of the welding torch, the rotary actuator has an aperture therein configured to fit around the upper portion of the welding torch, and the mounting assembly comprises a clamp for holding the rotary actuator in place on the upper portion of the welding torch.

6. The apparatus of any one of claims 1 to 5 wherein the camera assembly comprises one or more primary cameras configured to capture images of an area around the welding tip during the welding operation showing the size and shape of a weld pool and the position of the weld pool relative to a weld seam.

7. The apparatus of any one of claims 1 to 6, wherein the camera assembly comprises two or more cameras configured to simultaneously capture real-time images of a weld pool from different angles to generate a three dimensional view of the weld pool.

8. The apparatus of any one of claims 1 to 7 wherein the camera assembly comprises one or more additional cameras positioned to collectively capture images in front of the welding tip during the welding operation.

9. The apparatus of any one of claims 1 to 8 wherein the camera assembly comprises an integrated illumination system.

10. The apparatus of any one of claims 1 to 9 wherein the camera assembly comprises one or more additional sensors for sensing at least one of distance, heat, or sound.11 . The apparatus of any one of claims 1 to 10 wherein the actuator is configured to move the camera assembly to maintain a desired field of view from in front of the weld pool as the welding torch is actively welding a weld seam.

12. An apparatus comprising, a mounting assembly configured to engage with a welding torch, the welding torch comprising a welding tip; and, a camera assembly connected to the mounting assembly, the camera assembly comprising,one or more primary cameras directed at the welding tip and / or weld pool, and, one or more additional cameras directed at a weld path adjacent to the welding tip.

13. The apparatus of claim 12 wherein the camera assembly is operably connected to an actuator mounted on the mounting assembly.

14. The apparatus of claim 13 wherein the actuator is configured to move the camera assembly to capture real time images of the welding tip and / or the weld pool on the primary camera, and images of the weld path on the one or more additional cameras, from different angles.

15. The apparatus of any one of claims 12 to 14 wherein the one or more primary cameras comprise two or more primary cameras configured to simultaneously capture real-time images of athe weld pool from different angles to generate a three dimensional view of the weld pool.

16. The apparatus of any one of claims 12 to 15 wherein the one or more secondary cameras comprise two or more secondary cameras configured to simultaneously capture real-time images of the weld path adjacent to the welding tip from different angles to generate a three dimensional view of the weld path adjacent to the welding tip.

17. The apparatus according to any one of claims 12 to 16 wherein the camera assembly comprises an integrated illumination system.

18. The apparatus of any one of claims 12 to 17 wherein the camera assembly comprises one or more additional sensors for sensing at least one of distance, heat, or sound.

19. A method for controlling an active welding area, the method comprising, directing a welding operation, the welding operation comprising guiding a tip of a weld torch along a path to form a weld seam; capturing real time images of the tip of the weld torch during the welding operations; capturing pre-weld images of the path ahead of the tip of the weld torch; and, controlling the weld torch based on the pre-weld images of the path ahead of the tip of the weld torch and / or the real-time images of the tip of the weld torch.

Images