Inertial Weld Tool Tracking for Operator Guidance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual welding tools rely heavily on operator skill, leading to imprecision and variability in weld quality, and there is a need to reduce training costs and monitor welding processes for quality assurance and safety.
Innovation Solution
An intelligent hand-held tool equipped with sensors, such as inertial measurement units (IMUs), cameras, and processing subsystems, to track and guide the tool's motion, orientation, and position, enabling real-time feedback and adaptive control of welding parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual welding tools are used, then operator flexibility and skill application are improved, but weld precision and consistency deteriorate due to human error and variability
Solution Approach 1:
The system incorporates sensors (accelerometers, gyroscopes, magnetometers) that continuously monitor tool position, orientation, and motion, providing real-time feedback to guide the operator's hand movements along the desired weld path, thereby maintaining precision while preserving manual operation flexibility
Solution Approach 2:
The patent replaces purely mechanical manual control with an integrated sensor-based guidance system that uses inertial measurement units and computational algorithms to assist the operator, substituting mechanical precision requirements with electronic sensing and feedback control
2Manufacturing precision
If advanced welding skills are required, then weld quality is improved, but training costs and operator availability worsen
Solution Approach 1:
The system enables operators to achieve high-quality welds through real-time automated guidance and feedback, allowing them to self-correct their technique without extensive training, as the device actively guides their hand movements rather than requiring pre-acquired skill
3Reliability
If real-time monitoring is implemented, then quality assurance is improved, but device complexity worsens
Solution Approach 1:
The system integrates multiple functions (motion tracking, path guidance, quality monitoring, data recording) into a single multi-functional device, where the same sensor suite serves both guidance and quality assurance purposes, reducing overall system complexity despite comprehensive monitoring capabilities
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
This system reduces operator dependency, ensures consistent weld quality, and provides real-time monitoring and feedback for quality assurance, allowing less skilled operators to produce high-quality welds while reducing training costs and improving safety.
Implementation Method 1
An example of a commercially available 6D (6 degrees of freedom) IMU is Fairchild FIS1100, with 3-axis accelerometer, and 3-axis gyroscope in one package.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A welding system comprises a hand-held weld tool 102 comprises a positioning and orientation measurement system having an inertial measurement unit (IMU) 352, a processing subsystem, and a calibration apparatus 356. The processing subsystem is operable to compute, based on data generated by the IMU during a weld operation on a workpiece, one or more actual motion attributes for the hand-held weld tool. The calibration apparatus is configured to hold the hand-held weld tool in a known position and orientation and in stationary state for calibration of the positioning and orientation measurement system.