3D Torch Tracking for Accurate Welding Skill Measurement
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Solution Overview
Problem
Existing welding skill transfer methods are inefficient and inaccurate, leading to potential loss of manufacturing skills due to sensory coaching and insufficient data measurement.
Innovation Solution
A welding work measurement system utilizing photodetection units to detect markers on a torch and welding object, acquiring three-dimensional coordinate data for accurate positional relations, and integrating inertial sensors for quality control and education systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct coaching from skilled engineers is used to transfer welding skills, then personal guidance can be provided, but the skills are inaccurately handed down and time-consuming
Solution Approach 1:
The patent uses motion capture technology to create digital copies of skilled welders' movements and operations. These copies are stored as standardized training data that can be repeatedly used for training multiple apprentices without requiring the skilled engineer's continuous presence, thus improving accuracy while reducing time loss
Solution Approach 2:
The patent replaces the mechanical system of direct human-to-human coaching with an automated measurement and evaluation system using photodetection units, markers, and computers. This system objectively measures welding operations and compares them against standardized data, eliminating the inaccuracies and time constraints of sensory-based direct coaching
2Measurement precision
If various measurement devices are used to measure welding work, then skill evaluation becomes possible, but the measurement principles and positional accuracy are insufficient
Solution Approach 1:
The patent employs multiple photodetection units positioned at different locations to capture marker positions from multiple angles simultaneously. This multi-dimensional approach enables accurate three-dimensional position calculation through coordinate transformation, achieving high positional accuracy without requiring complex single-point measurement devices
Solution Approach 2:
The patent introduces markers as intermediary objects attached to the welding tool and workpiece. These markers serve as easily detectable reference points that mediate between the photodetection units and the actual welding components, simplifying the measurement system while enabling precise positional and angular measurements
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
Enables precise measurement and evaluation of welding operations, facilitating skill transfer, improving manufacturing quality, and reducing defect rates through digitalized data utilization.
Implementation Method 1
a photodetection unit that detects light generated by a plurality of markers attached to a torch for welding a welding object or light reflected by the plurality of markers
Data Source
AI summary
A welding work measurement system enables accurate measurement of a positional relation between respective parts. Therefore, a welding work measurement system includes a photodetection unit that detects light generated by a plurality of markers attached to a torch for welding a welding object or light reflected by the plurality of markers, a marker position acquisition unit that acquires marker position data that is three-dimensional coordinate data on the markers on the basis of the light detected by the photodetection unit, and a torch position acquisition unit that acquires torch position data that is three-dimensional coordinate data on the torch on the basis of the marker position data.