Helmet-Based Weld Tracking for Tool Motion Differentiation
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Solution Overview
Problem
Conventional weld tracking systems are limited in their ability to provide a portable and compact solution for tracking welding operations, often requiring fixed installations and struggling to differentiate between the movement of the welding helmet and the welding tool, which hampers analysis of welding technique, location, and sequence.
Innovation Solution
A helmet-based weld tracking system that includes sensors and control circuitry to track the position and orientation of both the welding helmet and the welding tool, allowing for differentiation between their movements and providing real-time feedback and adjustments to ensure proper welding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional weld tracking systems are used, then welding operations can be tracked, but the systems are not portable and require fixed installations
Solution Approach 1:
The patent combines the weld tracking system components into a portable unit that can be easily transported and deployed. The system integrates sensors, processors, and power sources into a compact configuration that eliminates the need for fixed installations while maintaining full tracking functionality.
Solution Approach 2:
The portable weld tracking system is designed to be universally applicable across different welding environments and configurations. It can track welding operations in various locations without requiring site-specific installations, making it adaptable to mobile and non-traditional welding environments.
2Measurement precision
If conventional weld tracking systems are used, then welding location can be tracked, but the systems cannot differentiate between helmet movement and tool movement
Solution Approach 1:
The system segments the tracking of different components by separately tracking the welding helmet and the welding tool using independent sensors and reference frames. This allows the system to distinguish between helmet movement and tool movement, enabling precise measurement of actual welding technique regardless of helmet position changes.
Solution Approach 2:
The system introduces intermediary reference frames and calibration procedures that act as mediators between the helmet sensors and tool sensors. These intermediaries enable the system to differentiate and decouple the movements of the helmet from the movements of the welding tool, improving measurement accuracy.
3Adaptability or versatility
If fixed installations are used for weld tracking, then stable tracking can be achieved, but the systems are not suitable for mobile welding environments
Solution Approach 1:
The portable weld tracking system employs dynamic calibration and reference frame adjustment capabilities that allow it to maintain tracking stability despite changes in environment and position. The system can adapt to mobile welding conditions while preserving reliable tracking through real-time adjustments.
Data Source
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AI summary
Described herein are examples of weld tracking systems. In some examples, a weld tracking system include weld tracking sensors configured to allow the weld tracking system to track a position and/or orientation of a welding-type tool, and/or an arc generated by the welding-type tool. In some examples, the weld tracking system evaluates certain welding technique and/or welding operation parameters based on the tracked position(s) and/or orientation(s), and/or offers corrective feedback. In some examples, one or more calibrations may be performed to aid in evaluation of the welding technique and/or welding operation parameters.