Helmet-Based Weld Tracking Calibration for Portable Precision

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Solution Overview

Problem

Conventional weld tracking systems lack a portable and compact solution for accurately tracking welding operations, particularly in environments where fixed systems are impractical, and they fail to provide real-time feedback and adaptive adjustments to improve welding technique and efficiency.

Innovation Solution

A helmet-based weld tracking system that includes sensors and processing units to track the position and orientation of both the helmet and the welding tool, allowing for real-time monitoring and feedback, and enabling adaptive adjustments to improve welding technique and efficiency by determining vector relationships between sensors and providing corrective feedback.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a fixed weld tracking system is used, then measurement precision is improved, but device complexity and portability are worsened

Engineering Contradiction:

Improvetracking accuracyVSAvoidsystem portability

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple sensor systems (first sensor system for helmet tracking, second sensor system for tool tracking) into an integrated helmet-based system. The processing circuitry merges data from both sensor systems to determine weld tracking information, eliminating the need for separate fixed tracking infrastructure while maintaining measurement precision through coordinated multi-sensor data fusion.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The welding helmet serves multiple functions: it provides protective equipment for the welder, houses the first sensor system for tracking helmet position and orientation, and integrates processing circuitry for real-time weld tracking. This multi-functional design replaces complex fixed infrastructure with a portable universal device that performs both safety and tracking functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If real-time monitoring is implemented, then productivity is improved, but use of energy is worsened

Engineering Contradiction:

Improvewelding efficiencyVSAvoidhelmet system power consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The processing circuitry automatically processes sensor data in real-time without requiring external computing infrastructure. The system self-sufficiently performs weld tracking, position determination, and feedback generation within the helmet unit, eliminating the need for continuous high-energy communication with external systems while maintaining real-time monitoring capabilities.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system processes sensor data at appropriate intervals for real-time tracking without requiring continuous maximum-power operation. By implementing partial action processing - analyzing data when welding events occur rather than maintaining constant high-level processing - the system achieves productivity improvement while managing energy consumption through selective rather than continuous computational intensity.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of operation

If calibration procedures are simplified, then ease of operation is improved, but measurement precision is worsened

Engineering Contradiction:

Improvecalibration complexityVSAvoidvector relationship accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces complex manual calibration procedures with an automated optical/magnetic sensing system. The sensor systems automatically detect positions and orientations of the helmet and welding tool, and the processing circuitry automatically calculates vector relationships between sensors. This substitution of mechanical calibration with automated sensing and computational geometry simplifies operator tasks while maintaining precision through algorithmic accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a digital copy or model of the physical spatial relationships between sensors, helmet, and tool through coordinate mapping. By representing physical positions as digital coordinates and vector relationships as mathematical transformations, the system enables automated calibration that is both simple to operate and precise, as the digital model can be processed algorithmically without manual measurement errors.

Inventive Principle:

Principle #26Copying

Data Source

PatentEP4238680B1Non transitory computer readable medium, method and welding system for calibration procedures for helmet based weld tracking systems

Publication Date: 2025.01.01 ILLINOIS TOOL WORKS INC

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AI summary

Described herein are examples of weld tracking systems implemented via a welding helmet. The welding helmet includes weld tracking sensors configured to allow the welding helmet to track a welding-type tool and/or an arc generated by the welding-type tool. The welding helmet also includes helmet tracking sensors configured to allow the welding helmet to track its own position and/or orientation relative to a reference point in the welding environment. By tracking itself as well as the welding-type tool and/or arc, the welding helmet can differentiate between its own movement, and movement of the welding-type tool and/or arc. By knowing the spatial relationship between the different sensors of the welding helmet, the tracking information can be combined and used for weld tracking. By implementing the weld tracking system in the welding helmet, the weld tracking system becomes portable and usable outside of the usual fixed confines of weld tracking systems.