Helmet-Based Weld Tracking for Tool and Arc Position Feedback
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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 infrastructure and struggling to differentiate between the movement of the welding helmet and the welding tool, which affects the 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, providing corrective feedback and adjusting parameters or disabling welding when deviations occur, using a calibration process to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional weld tracking systems use fixed infrastructure, then system stability is improved, but portability and compactness deteriorate
Solution Approach 1:
The patent merges the weld tracking system components (sensors, processors, power supply) directly into the welding helmet, creating an integrated portable system that eliminates the need for fixed infrastructure while maintaining functional stability
Solution Approach 2:
The welding helmet serves multiple functions: it provides welding protection, houses the tracking system sensors, processes data, and displays information. This multi-functionality enables portability without sacrificing system capabilities
2Device complexity
If the system tracks only welding tool position, then device complexity is reduced, but measurement precision deteriorates due to inability to differentiate helmet movement from tool movement
Solution Approach 1:
The tracking system is segmented into multiple independent tracking components: one sensor tracks helmet position and orientation, while another tracks welding tool position. This segmentation allows the system to differentiate between helmet movement and tool movement, improving measurement precision without excessive complexity
Solution Approach 2:
The system uses an intermediary calibration process that establishes the spatial relationship between the helmet and tool. This calibration data acts as a mediator that enables accurate differentiation between helmet and tool movements during welding operations
3Manufacturing precision
If the system provides real-time feedback and parameter adjustments, then welding quality is improved, but device complexity increases
Solution Approach 1:
The system implements real-time feedback by monitoring welding parameters (position, orientation, speed) and providing corrective feedback to the operator through the helmet display. This feedback loop improves welding quality by enabling immediate correction of deviations without requiring complex external monitoring systems
Solution Approach 2:
The welding helmet itself serves as the feedback interface, displaying information and providing guidance directly to the operator. This self-service approach eliminates the need for separate complex feedback systems while maintaining quality improvement capabilities
Data Source
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.