Marker Ring Calibration for Portable Welding Technique Monitoring
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Solution Overview
Problem
Conventional welding technique monitoring systems are cumbersome, require calibration for each welding station, and often necessitate modifications to existing welding equipment, making them difficult to use with standard tools and increasing costs.
Innovation Solution
A portable welding technique monitoring system that uses a marker ring calibration process, allowing for consistent monitoring of welding technique without additional calibration, even with sensor and platform movement, and is compatible with existing welding tools, utilizing off-the-shelf mobile devices for electronic functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding technique monitoring systems are used, then welding technique can be monitored, but the systems are cumbersome and require calibration for each welding station
Solution Approach 1:
The system performs preliminary calibration by capturing images of the marker ring at multiple known positions and orientations before actual welding monitoring. This pre-calibration creates a mapping between marker ring positions and welding tool positions, eliminating the need for recalibration at each welding station and simplifying subsequent operations.
Solution Approach 2:
The system uses a camera to capture visual images of the marker ring and creates a digital representation of the marker ring's position and orientation. This optical copying approach replaces complex mechanical measurement systems, reducing device complexity while maintaining monitoring accuracy across multiple welding stations.
2Adaptability or versatility
If conventional welding technique monitoring systems are used, then welding technique can be monitored, but modifications to existing welding equipment are necessary
Solution Approach 1:
The system separates the monitoring function from the welding equipment itself. The marker ring is attached independently to the welding tool, and the camera system is positioned separately to capture images. This segmentation allows the monitoring system to work with existing welding equipment without modifications, improving adaptability while simplifying manufacturing and deployment.
Solution Approach 2:
The marker ring serves multiple functions: it provides visual targets for the camera to track, establishes spatial relationships for calibration, and enables monitoring of welding tool position and orientation. This multi-functionality allows a single simple component to replace complex integrated systems, making the solution universally applicable to various welding stations without requiring equipment modifications.
3Measurement precision
If conventional welding technique monitoring systems are used, then welding technique can be monitored, but calibration is required for each welding station increasing costs
Solution Approach 1:
The system performs comprehensive calibration once by capturing marker ring images at multiple predetermined positions and orientations. This preliminary calibration creates a reusable mapping that maintains measurement precision across different welding stations without requiring repeated calibration processes, thereby reducing time loss and operational costs.
Solution Approach 2:
The system continuously captures images of the marker ring during welding operations and compares the captured positions against the pre-established calibration data. This feedback mechanism maintains measurement precision by dynamically tracking deviations from the calibrated positions, eliminating the need for frequent recalibration while preserving accurate measurements across multiple stations.
Data Source
AI summary
Described herein are examples of welding technique monitoring systems that provide lightweight, self-contained, and highly portable means of monitoring welding technique and/or providing technique feedback. The systems use a portable support platform that can be easily transported to different welding stations/sites, providing a marked advantage over legacy monitoring systems that use heavy welding stands that are difficult to move. After an initial calibration, the systems can consistently and repeatedly monitor welding technique relative to a particular joint with no additional calibration necessary, even if there is sensor and/or platform movement. The systems are additionally able to detect a welding-type operation without the need to communicate with welding equipment. The systems are further configured for use with existing (rather than potentially expensive custom) welding-type tools, thereby keeping the systems low cost and highly portable. The systems are further configured to use off the shelf mobile devices, thereby simplifying power/battery management.