Acoustic Weld Tracking for Precise Technique Feedback
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Solution Overview
Problem
Conventional welding technique monitoring systems struggle to accurately assess and improve the welding technique of operators, particularly less experienced ones, as they often find it difficult to judge good or bad technique, impacting weld quality.
Innovation Solution
The implementation of an acoustic tracking system using tracking anchors and tags that transmit and receive signals to determine the location and orientation of welding devices, allowing for real-time monitoring and feedback on welding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional welding technique monitoring systems are used, then the system structure is simple, but the measurement precision of welding technique parameters is insufficient
Solution Approach 1:
The patent replaces conventional mechanical/optical tracking systems with an acoustic tracking system that uses sound waves to monitor welding device position and orientation. Acoustic tracking anchors and tags transmit and receive acoustic signals to calculate spatial coordinates, providing precise welding technique parameters without complex mechanical structures.
Solution Approach 2:
The patent introduces acoustic signals as an intermediary medium between the welding device and the monitoring system. Acoustic tracking tags attached to welding devices communicate with acoustic anchors through sound wave transmission and reception, enabling indirect but precise measurement of welding parameters without direct mechanical or optical contact.
2Measurement precision
If acoustic tracking systems are implemented, then the measurement precision of welding technique parameters is improved, but the device complexity increases
Solution Approach 1:
The acoustic tracking system serves multiple functions simultaneously: it tracks welding device position, determines orientation angles, monitors welding technique parameters, and provides real-time feedback. This multi-functionality reduces the need for separate monitoring systems, making the increased complexity worthwhile by consolidating multiple measurement capabilities into a single integrated system.
Solution Approach 2:
The acoustic tracking tags on welding devices autonomously transmit their position and orientation data to the monitoring system without requiring external calibration or manual intervention. The system automatically calculates welding technique parameters from the acoustic signal measurements, enabling self-service operation that reduces operational complexity despite the sophisticated hardware involved.
3Productivity
If real-time monitoring and feedback are provided, then the productivity of welding operations is improved, but the use of energy increases
Solution Approach 1:
The acoustic tracking system uses periodic transmission of acoustic signals between anchors and tags to monitor welding device position. Rather than continuous transmission, the system periodically updates position data at intervals sufficient for real-time monitoring while allowing energy conservation during intervals between measurements, balancing productivity improvement with energy consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system provides precise tracking and feedback on welding technique parameters, enhancing weld quality by enabling operators to adjust their techniques effectively, even for less experienced users.
Implementation Method 1
determine distances between each of the tracking anchors and the tracking tag based on a time between the response signal being received and the triggering signal being sent or received
Data Source
AI summary
Disclosed example weld tracking system include a plurality of tracking anchors, each of the tracking anchors configured to: transmit a triggering signal, and transmit a response signal, or receive a response signal from a tracking tag; a welding device having the tracking tag attached to the welding device, the tracking tag configured to receive the triggering signal and receive the response signal, or receive the triggering signal and transmit the response signal in response to receiving the triggering signal; and a processing system configured to determine a distance between the tracking anchor and the tracking tag based on a time between the response signal being received and the triggering signal being sent or received, and determine a location of the welding device based on predetermined locations of the plurality of tracking anchors, and based on determined distances between the at least one tracking tag on the welding device and corresponding ones of the plurality of tracking anchors.