Helmet-Integrated Torch Tracking for Weld Travel Speed Feedback

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Solution Overview

Problem

Manual welding operations face challenges in accurately measuring weld travel speed due to environmental and operator-related factors, making it difficult to monitor and control the welding process effectively.

Innovation Solution

A helmet-integrated travel speed sensing system that uses sensors on the welding helmet to determine the position and orientation of the welding torch relative to the workpiece, processing signals from various sensors such as optical and microphone sensors to calculate the travel speed, and providing real-time feedback to the operator through a display.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual welding operations are performed without automated control, then operator flexibility and adaptability are maintained, but accurate measurement and control of weld travel speed becomes difficult

Engineering Contradiction:

Improveoperator flexibilityVSAvoidweld travel speed measurement

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent introduces an optical sensor as an intermediary device that indirectly measures weld travel speed by detecting the motion of the welding torch through optical signals. This mediator enables accurate measurement without directly interfering with the operator's manual welding process, thus maintaining operator flexibility while achieving precise speed measurement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces mechanical measurement methods with an optical sensing system. Instead of using mechanical encoders or position sensors that would require direct attachment to the torch and interfere with operation, the system uses optical fields to detect torch position and calculate travel speed, thereby maintaining ease of operation while improving measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If sensors are integrated into the welding helmet, then real-time monitoring of welding parameters is achieved, but device complexity increases

Engineering Contradiction:

Improvereal-time monitoring capabilityVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the welding helmet: the optical sensor, microphone sensor, display device, and processing system are all integrated into a single helmet unit. This merging approach enables real-time monitoring of welding parameters while consolidating the system structure, making the complex functionality more manageable and user-friendly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The welding helmet is designed to perform multiple functions: it serves as protective equipment, houses optical sensors for position detection, contains microphone sensors for audio monitoring, provides display capabilities for real-time feedback, and processes sensor data. This multi-functionality reduces the need for separate devices and simplifies the overall system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Measurement precision

If multiple sensors are used to detect welding parameters, then measurement accuracy is improved, but ease of operation deteriorates due to increased system complexity

Engineering Contradiction:

Improvewelding parameter detection accuracyVSAvoidoperator convenience

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system automatically processes sensor data and generates real-time feedback without requiring manual intervention from the operator. The processing system autonomously calculates weld travel speed from optical sensor data, analyzes audio signals from the microphone sensor, and displays results on the helmet display device. This self-service capability maintains ease of operation while achieving high measurement precision through multiple sensors.

Inventive Principle:

Principle #25Self-service

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

Enables accurate monitoring and control of weld travel speed in manual welding operations, improving weld quality by providing operators with real-time feedback and enhancing the consistency of weld parameters.

Implementation Method 1

a first sensor associated with a welding helmet and configured to sense a parameter indicative of a position of a welding torch relative to the welding helmet

Methodology Applied

Scientific EffectOptical sensing: Photoelectric Effect

Implementation Method 2

a microphone sensor associated with the welding helmet and configured to sense a sound emitted by a sound source

Methodology Applied

Scientific EffectAcoustic detection: Sound

Data Source

PatentUS11590596B2Helmet-integrated weld travel speed sensing system and method

Publication Date: 2023.02.28 ILLINOIS TOOL WORKS INC

AI summary

A welding system includes a first sensor associated with a welding helmet and configured to sense a parameter indicative of a position of a welding torch relative to the welding helmet. The travel speed sensing system also includes a processing system communicatively coupled to the first sensor and configured to determine a position of the welding torch relative to a workpiece based on the sensed first parameter.