Modular Welding Simulation Training With Desktop AR Workpieces
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Solution Overview
Problem
The welding industry faces a shortage of skilled operators and high costs associated with training new welders using live equipment, while experienced welders struggle to maintain welding techniques consistently.
Innovation Solution
A weld training system utilizing desktop and mobile devices with modular workpieces and simulated welding equipment, featuring marker-based mock workpieces that connect toollessly, enabling simulations of welding operations through augmented, mixed, or virtual reality, and providing feedback on spatial relationships and training scores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional simulated welding systems are used, then welding training capability is provided, but equipment investment cost is substantial
Solution Approach 1:
The patent uses mock workpieces that are simplified copies of real welding workpieces, featuring markers that can be detected by the computing device. These mock workpieces replicate the essential geometric and spatial characteristics needed for training without requiring expensive real welding equipment, sensors, and processing systems. The copying principle allows the system to provide authentic welding training experiences while dramatically reducing equipment costs.
Solution Approach 2:
The mock workpieces are designed with universal connectors that enable tool-less connection and reconfiguration. This universality allows the same mock workpiece components to be used across multiple training scenarios and configurations, replacing the need for numerous specialized training equipment pieces. The system can adapt to different welding positions, joint types, and training objectives using the same core components.
2Reliability
If real welding equipment is used for training, then authentic welding experience is provided, but training cost is expensive
Solution Approach 1:
The system creates virtual representations of welding operations using markers on mock workpieces that are detected by the computing device. These markers encode spatial and geometric information that allows the software to simulate authentic welding experiences, including weld bead formation, penetration depth, and joint quality assessment, without requiring actual welding equipment. The copying approach maintains training authenticity while eliminating the need for expensive real equipment.
Solution Approach 2:
The patent replaces the mechanical welding system with a computational detection and simulation system. Instead of using physical welding equipment to create and measure welds, the system uses image processing, marker detection, and virtual simulation to replicate the welding process. This substitution eliminates the need for costly welding machinery, power supplies, and safety equipment while providing comparable or superior training value.
3Ease of operation
If modular mock workpieces with connectors are used, then tool-less connection is enabled, but marker positioning complexity increases
Solution Approach 1:
The connectors on the mock workpieces are designed with asymmetric features that provide visual and tactile guidance for proper alignment. This asymmetry makes it intuitively obvious how to connect components correctly without requiring complex instructions or precise marker positioning. The asymmetric connector design naturally guides users into the correct configuration, simplifying both the connection process and the underlying marker placement requirements.
Data Source
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AI summary
Systems for simulating joining operations, such as welding, are disclosed. In some examples, a system may use a desktop device for conducting welding simulations, such as for purposes of training. In some examples, the system may additionally, or alternatively, use modular workpieces. In some examples, the system may additionally, or alternatively, conduct the welding simulation based on one or more selected pieces of welding equipment.