Sensor Welding Torch Feedback for Real-Time Weld Training

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Solution Overview

Problem

Welding training systems are often expensive and inadequate in training operators to perform high-quality welds, with limited availability and ineffective training methods.

Innovation Solution

A welding system equipped with a sensor-enabled welding torch that detects motion and temperature, providing vibration and audible feedback to guide operators, and integrated with software for training modes, including virtual reality, to enhance training effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional welding training systems are used, then training can be provided, but the systems are expensive and inadequate in training operators to perform high quality welds

Engineering Contradiction:

Improvequality of weldsVSAvoidcost and complexity of training system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The welding torch incorporates sensors that detect welding parameters and provide real-time feedback to the operator through visual displays and haptic vibrations. This feedback mechanism enables operators to learn and improve welding quality by immediately observing the effects of their actions, eliminating the need for expensive traditional training systems while achieving high-quality weld results.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The training system enables operators to self-instruct through real-time feedback on welding parameters and quality metrics displayed on the torch. Operators can independently practice and improve their skills without requiring expensive instructor-led training programs or complex training infrastructure, making the system both cost-effective and highly effective for skill development.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If welding training systems are acquired, then training capability is provided, but the systems are expensive leading to limited availability

Engineering Contradiction:

Improvetraining availabilityVSAvoidcost of training system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The welding torch is designed as an affordable, portable training device that can be widely distributed without requiring expensive institutional infrastructure. The torch incorporates all necessary sensors and feedback mechanisms in a single, self-contained unit that can be used independently, making training accessible to a broad audience rather than being limited to institutions that can afford costly training systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If real-time feedback is provided through sensors, then training effectiveness is improved, but device complexity increases

Engineering Contradiction:

Improvetraining effectivenessVSAvoidcomplexity of welding torch

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The welding torch integrates multiple functions including welding execution, parameter sensing, real-time feedback display, and haptic feedback in a single universal device. This multi-functionality consolidates what would otherwise require separate training equipment into one tool, improving training effectiveness without proportionally increasing complexity, as the same hardware serves multiple purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system replaces complex mechanical training apparatus with electronic sensors and digital feedback mechanisms. Instead of using elaborate mechanical training rigs, the invention uses electronic sensors to detect welding parameters and digital displays plus haptic feedback to communicate with the operator, simplifying the overall system while enhancing training effectiveness through precise measurement and immediate feedback.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system provides cost-effective and comprehensive training, improving the quality of welds by offering real-time feedback and immersive training experiences, thereby enhancing operator proficiency.

Implementation Method 1

a sensor configured to detect a motion associated with the welding torch

Methodology Applied

Scientific EffectMotion detection: Accelerometer

Implementation Method 2

a temperature associated with the welding torch

Methodology Applied

Scientific EffectTemperature detection: Thermocouple

Implementation Method 3

vibrating the welding torch at a first pattern if the parameter is within the first predetermined range

Methodology Applied

Scientific EffectVibration feedback: Vibration

Data Source

PatentUS20230267852A1Feedback from a welding torch of a welding system

Publication Date: 2023.08.24 ILLINOIS TOOL WORKS INC

AI summary

A welding system includes a welding torch. The welding torch includes a sensor configured to detect a motion associated with the welding torch, a temperature associated with the welding torch, or some combination thereof. A display of the welding torch is activated, a determination is made that the welding torch has been involved in a high impact event, live welding using the welding torch is disabled, a software selection is made, or some combination thereof, based on the motion, the temperature, or some combination thereof.