Mobile Weld Training With Camera-Based Torch Tracking
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Solution Overview
Problem
Existing weld training systems are large, expensive, and not suitable for high-volume production, limiting their accessibility and effectiveness in training and recruiting for manual welding operations.
Innovation Solution
A mobile device coupled to a welding torch that detects dynamic position and orientation information using sensors and cameras, providing a simulated or augmented welding experience, including real-time feedback and virtual reality environments, to enable cost-effective and efficient training.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional weld training systems are used, then training effectiveness is maintained, but cost and device complexity increase
Solution Approach 1:
The patent uses a mobile device to create a virtual copy of the welding environment and training system. Instead of requiring expensive physical training equipment, the system renders a virtual welding scene on a smartphone or tablet screen, allowing trainees to practice welding techniques through visual simulation and haptic feedback without needing complex physical apparatus
Solution Approach 2:
The patent replaces complex mechanical training systems with software-based simulation. The mobile device uses camera sensors to detect real-world welding torch movements and translates them into virtual training scenarios, substituting physical training rigs with optical sensing and software rendering to achieve the same training objectives
2Reliability
If traditional weld training systems are used, then training quality is maintained, but manufacturing cost increases
Solution Approach 1:
The patent makes the mobile device serve multiple functions: it acts as the training display, sensor array, processor, and haptic feedback device all in one. The same smartphone or tablet that people already carry can detect torch position via camera, render virtual welding environments, provide visual feedback, and deliver haptic feedback through its built-in vibration motor, eliminating the need for dedicated expensive training equipment
Solution Approach 2:
The mobile device uses its own built-in components (camera, display, vibration motor) to provide all training functions without requiring external specialized equipment. The device serves itself by utilizing existing hardware capabilities for sensing, processing, display, and feedback, thereby eliminating the need for additional manufactured training system components
3Ease of manufacture
If mobile device-based training is implemented, then cost and accessibility improve, but measurement precision may be affected
Solution Approach 1:
The patent introduces visual markers or fiducial targets as intermediaries between the welding torch and the mobile device camera. These markers provide reference points that the camera can accurately detect and track, enabling precise determination of torch position and orientation without requiring the camera itself to have high-precision measurement 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
The mobile device-based weld training system offers a low-cost, high-volume solution for training and recruiting, providing real-time feedback and simulated or augmented welding experiences that enhance operator skills and reduce training costs.
Implementation Method 1
The mobile device includes a camera configured to detect one or more of a plurality of identifiers disposed on the orientation device
Implementation Method 2
The mobile device is configured to detect, via one or more sensors, dynamic position or orientation information of the welding torch during the welding procedure
Data Source
AI summary
An example weld training system includes: an orientation device; a mobile device; and a mount configured to attach the mobile device to a welding accessory, wherein the mobile device comprises: one or more sensors including at least a camera; a processor; and a machine readable storage device storing machine readable instructions which, when executed by the processor, cause the processor to: recognize identifiers on the orientation device based on images captured via the camera; determine at least one of position information or orientation information for a welding torch with respect to the orientation device based on the recognized identifiers; and display, via a display of the mobile device, a welding operation based on the at least the position information or the orientation information.