Virtual Weld Marking With Camera Guidance for Weld Sequence Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding systems face challenges in marking workpieces for simulated or resistant materials, as traditional marking methods are not applicable, leading to potential errors in weld sequence and location, which can result in warpage and distortion.
Innovation Solution
A virtual marking system that uses a display screen to generate markings based on selected locations, allowing for dynamic input and adjustment of marking properties, and integrates with cameras to recognize and track the welding torch, enabling accurate guidance for operators during welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional marking methods (pen, marker) are used on workpieces, then markings can be applied to guide welding locations and sequences, but this method is not applicable to simulated welding operations or workpieces that are resistant to conventional markings
Solution Approach 1:
The patent uses a camera to capture an image of the workpiece and displays it on a screen, creating a visual copy of the workpiece. Virtual markings are then overlaid on this digital copy rather than physically marking the actual workpiece. This allows markings to be applied in simulated welding operations and to workpiece surfaces that are resistant to conventional marking methods, while maintaining accurate guidance for weld locations and sequences.
2Adaptability or versatility
If virtual marking is implemented using camera and display screen, then markings can be applied to simulated welding operations and resistant workpieces, but system complexity increases
Solution Approach 1:
The welding system is enhanced with a camera and display screen that serve multiple functions: capturing workpiece images, displaying virtual markings, guiding welding operations, and enabling both simulated and actual welding applications. This multi-functional approach consolidates what could be separate systems into an integrated solution, managing complexity through unified device design.
3Loss of information
If virtual markings are displayed on a screen, then real-time guidance can be provided for welding operations, but information loss may occur compared to direct visual reference on the workpiece
Solution Approach 1:
The patent replaces direct physical marking on the workpiece with a digital imaging and display system. The camera captures the workpiece image and the display screen presents virtual markings overlaid on this image. This substitution maintains visual accuracy through pixel-level positioning while enabling real-time guidance, as the display can be dynamically updated without physical contact with the workpiece.
Data Source
AI summary
Apparatus, systems, and/or methods are disclosed relating to welding systems that allow for virtual marking of welding workpieces. In some examples, a virtual marking process of the welding system generates and/or displays one or more markings on a display of the welding system in response to a dynamic input. In some examples, the dynamic input may comprise one or more of a user input received via a user interface, a marking instrument, and/or a welding gun of the welding system. In some examples, the dynamic input may comprise images captured by the welding system and recognized by the welding system as indicating markings. In some examples, the markings may guide an operator by indicating weld locations and/or weld order. In some examples, the markings may include embedded marking data (and/or metadata) that may be accessed and/or displayed to provide additional information and/or guidance to the operator.