Portable Welding Monitoring with Calibration-Free Joint Tracking
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Solution Overview
Problem
Conventional welding technique monitoring systems are often cumbersome, difficult to move between welding stations, and require modification of existing equipment, making them impractical for portable and cost-effective use.
Innovation Solution
A lightweight, self-contained portable welding technique monitoring system that uses a portable support platform, joint alignment guides, marker stands, and off-the-shelf mobile devices for electronic functions, allowing for calibration and monitoring without needing to communicate with welding equipment, and compatible with existing welding tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding technique monitoring systems are used, then monitoring capability is achieved, but portability and ease of movement between welding stations deteriorates
Solution Approach 1:
The monitoring system is divided into separate functional modules: a portable support platform with mounting structures, a mobile device (tablet or smartphone) for data processing and display, and separate sensor components. This segmentation allows each component to be optimized independently and facilitates easy movement between welding stations without requiring the entire system to be relocated as a single complex unit.
Solution Approach 2:
The portable support platform is designed with universal mounting structures that can accommodate various sensor types and configurations. The mobile device serves multiple functions including real-time monitoring, data storage, analysis, and feedback provision. This multi-functionality reduces the need for station-specific equipment, enhancing portability across different welding locations.
2Adaptability or versatility
If existing welding equipment is modified to enable monitoring, then monitoring functionality is achieved, but equipment cost and modification complexity increases
Solution Approach 1:
The system introduces an intermediary portable monitoring platform that interfaces with existing welding equipment through non-invasive methods such as optical sensors and external cameras. This intermediary approach enables monitoring functionality without requiring modifications to the welding tools themselves, maintaining compatibility while avoiding costly equipment changes.
Solution Approach 2:
Instead of modifying existing welding equipment, the system creates a separate digital replica or model of the welding process using external sensors and mobile device software. This copying approach captures welding technique data without altering the original equipment, preserving tool integrity while achieving monitoring objectives.
3Measurement precision
If calibration is required at each welding station, then measurement accuracy is maintained, but time consumption and operational efficiency deteriorates
Solution Approach 1:
The system performs preliminary calibration using joint alignment guides and marker stands that establish reference positions before actual welding begins. By pre-establishing these reference points and calibrating the mobile device once during initial setup, the system eliminates the need for repeated calibration at each welding station, thereby maintaining measurement accuracy while significantly reducing time consumption.
Solution Approach 2:
The portable support platform incorporates self-aligning features and automatic reference point detection capabilities that enable the system to maintain calibration without manual intervention at each station. The mobile device automatically references previously established calibration data, allowing the system to serve itself and maintain precision across multiple welding locations without additional calibration time.
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 for all the electronic functions, thereby simplifying power/battery management.