Augmented Reality Weld Sequencing Interface
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Solution Overview
Problem
Welders often overlook or misunderstand written or visual sequencing information during welding processes, leading to incomplete sequences, defects, and inefficiencies due to the lack of clear visual cues in complex welding operations.
Innovation Solution
An augmented reality system that uses an imaging device and processor to provide visual cues overlaid onto the assembly, guiding the welder through the correct sequence of operations by determining the orientation and field of view, and verifying the completion of each operation using infrared imaging data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If written descriptions and diagrams are provided to the welder, then welding sequence information is available, but the information is often overlooked or misunderstood
Solution Approach 1:
The patent transitions welding sequence information from traditional 2D written descriptions and diagrams to a 3D augmented reality overlay that appears directly on the assembly in the welder's field of view. This spatial dimensionality change makes the information impossible to overlook and provides intuitive spatial context for weld locations and sequences.
Solution Approach 2:
The system introduces an augmented reality display as an intermediary between the welding sequence data and the welder. This mediator presents the information in a visually intuitive format overlaid on the actual assembly, eliminating the need for the welder to interpret written descriptions or diagrams.
2Productivity
If the welder becomes familiar with the welding sequence, then efficiency improves, but attention to sequence details decreases
Solution Approach 1:
The system provides continuous visual feedback through the augmented reality display, showing the current weld number, sequence status, and next required operation. This feedback mechanism maintains sequence accuracy even as the welder gains familiarity with the process, preventing automatic pilot errors.
Solution Approach 2:
The system prepares and displays welding sequence information in advance, showing the welder the next required operation before it becomes critical. This preliminary presentation of information allows the welder to maintain both speed and accuracy by anticipating the next step.
3Loss of information
If visual cues are provided on a video screen, then welding information is enhanced, but the cues may still be overlooked or ignored
Solution Approach 1:
The patent moves the display from a separate 2D video screen to a 3D augmented reality overlay that appears directly on the assembly in the welder's field of view. This eliminates the need for the welder to shift attention between the screen and the workpiece, making the information impossible to overlook.
Solution Approach 2:
The system merges the welding sequence information display with the actual welding workspace by overlaying visual cues directly onto the assembly. This combination eliminates the separation between information and task, ensuring the welder never loses context.
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
The system ensures accurate and efficient welding by providing clear visual cues directly on the assembly, reducing errors and improving production quality by ensuring each operation is performed correctly and in the correct order.
Implementation Method 1
an imaging device... obtains image data from the imaging device, the image data including at least a part of an assembly to be welded that is visible in a field of view of a welder
Implementation Method 2
the processor generates a first visual cue and causes the first visual cue to be displayed on the display
Implementation Method 3
The AR system supports other weld-related functions such as the use of infrared imaging data to verify welding operations
Data Source
AI summary
A system for providing visual cues to a welder via an augmented reality display for a sequence of operations. The system includes an imaging device that identifies the orientation of an assembly to be welded. Welding operations are associated with locations on the assembly where the welder is to perform the operation. Based on the current field of view and the orientation of the assembly, the system determines whether the location on the assembly is within the field of view of the welder and provides a visual cue to the welder based on the orientation and the field of view. The power source of the welding device may be varied based on the image data received during the welding process.