Virtual Weld Location Guidance for Correct Welding Sequence
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Solution Overview
Problem
Conventional welding systems lack effective methods for monitoring and ensuring the correct location and order of welds, particularly in simulated or challenging environments where traditional markings are not feasible, leading to potential warpage and distortion issues.
Innovation Solution
A welding system that utilizes processing circuitry and machine-readable instructions to monitor weld locations and orders, providing a performance score and displaying visual identifiers, and allows for virtual marking of workpieces using cameras and user inputs to guide operators, ensuring adherence to predetermined criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional markings (pen, marker) are used to guide weld locations, then operators can be guided during welding, but this method is not applicable to simulated welding operations or workpieces resistant to conventional markings
Solution Approach 1:
The patent uses digital copies and virtual representations of workpieces displayed on electronic screens to guide welding operations. Instead of physically marking the actual workpiece, the system creates a virtual model with marked weld locations that operators can view and follow, making the guidance applicable to both real and simulated welding scenarios.
Solution Approach 2:
The patent replaces conventional mechanical marking methods (pens, markers) with an electronic display system. The guidance information is transmitted digitally through screens or augmented reality interfaces, eliminating the need for physical contact with the workpiece and enabling use with materials resistant to conventional markings.
2Manufacturing precision
If no monitoring system is implemented, then the welding process is simple and fast, but weld locations and sequences cannot be verified, leading to warpage and distortion
Solution Approach 1:
The patent implements a monitoring system that tracks weld locations and sequences in real-time, comparing actual welding operations against the predetermined plan. The system provides feedback to operators through the electronic display, indicating whether welds are being performed at correct locations in the correct sequence, thereby ensuring precision without requiring overly complex intervention mechanisms.
Solution Approach 2:
The system automatically monitors and verifies welding operations without requiring additional manual inspection steps. The electronic display and processing circuitry continuously track weld parameters and locations, performing self-verification of welding quality and providing real-time guidance, reducing the need for separate complex inspection equipment.
3Measurement precision
If virtual marking is implemented using cameras and user inputs, then operators receive real-time guidance, but the system complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single electronic display system. The same display that shows virtual markings also provides real-time feedback on weld progress, alerts for deviations from the welding plan, and guidance information. This multi-functionality reduces the need for separate monitoring devices and simplifies the overall system architecture despite the sophisticated capabilities provided.
Data Source
AI summary
Apparatus, systems, and/or methods are disclosed relating to welding systems that monitor welds performed by an operator. In some examples, the welding system monitors one or more welds performed using a welding tool, evaluates characteristics of the one or more welds in comparison to certain predetermined criteria, and determines a performance score for the operator based on the evaluation. In some examples, the characteristics of the one or more welds include the location of each of the one or more welds and/or the order in which the one or more welds are executed. In such an example, the predetermined criteria may include target locations for each of the one or more welds and/or a target order of execution. In some examples, the welding system may respond to deviations from the target locations and/or target order, such as by reducing a performance score, disabling weld operations, providing guidance to the operator.