Virtual Weld Marking on Displayed Workpieces for Sequence Guidance
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Solution Overview
Problem
Conventional welding systems face challenges in marking weld locations and sequences on workpieces, especially in simulated operations or when workpieces are resistant to conventional markings.
Innovation Solution
The implementation of a virtual marking system in welding systems, which uses a display screen to generate markings based on dynamic inputs, allowing for real-time guidance of weld locations and sequences without physical markings on the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional physical markings are used on workpieces, then weld locations and sequences can be clearly indicated, but this approach fails when workpieces are resistant to markings or in simulated welding operations
Solution Approach 1:
The patent uses a digital copy or representation of the workpiece displayed on a screen instead of marking the physical workpiece. The system captures an image of the workpiece and overlays virtual markings on the digital representation, allowing operators to see weld locations without physically marking the actual workpiece. This resolves the contradiction by providing marking functionality through a digital copy that works for all workpiece types including those resistant to physical marking and simulated workpieces.
Solution Approach 2:
The patent replaces the mechanical marking system (pens, markers, physical writing utensils) with a digital display system. Instead of using physical tools to mark the workpiece, the system uses a camera to capture the workpiece image and a display screen to show virtual markings overlaid on the captured image. This substitution eliminates the limitation of physical marking resistance while maintaining the guidance function.
2Loss of information
If physical markings are applied to guide welding operations, then weld locations are clearly visible, but the markings may interfere with the workpiece surface or be incompatible with certain materials
Solution Approach 1:
The system creates a digital copy of the workpiece surface and displays it on a screen with virtual markings overlaid. This allows complete guidance information delivery without any physical contact with the actual workpiece surface, eliminating surface contamination and material incompatibility issues while maintaining full visibility of weld locations and sequences.
Solution Approach 2:
The patent introduces a digital intermediary (the captured image displayed on screen) between the operator and the workpiece. Instead of directly marking the workpiece surface, the system mediates the guidance function through a digital representation that can display any type of marking without affecting the physical workpiece, thus eliminating harmful factors while preserving information delivery.
3Adaptability or versatility
If virtual markings are implemented on a display screen, then markings can be applied to any workpiece without physical contact, but the system requires additional equipment and processing
Solution Approach 1:
The patent makes the welding system multi-functional by integrating camera capture, image processing, and virtual marking display capabilities into the existing welding guidance system. The same system that guides welding operations also captures workpiece images and generates virtual markings, eliminating the need for separate marking equipment and reducing overall system complexity despite adding virtual marking functionality.
Solution Approach 2:
The patent merges the marking function with the existing imaging and display system used for welding guidance. Instead of adding a completely separate virtual marking system, the invention combines the marking capability with the camera and screen already present in modern welding systems, thereby achieving universal adaptability while minimizing the increase in device complexity.
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.