Virtual Weld Training With Simulated Bead Anomaly Feedback
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Solution Overview
Problem
Conventional weld training systems are costly and require high complexity, making them unsuitable for teaching fundamental welding concepts without providing unnecessary realism, and they often fail to simulate realistic welding environments effectively.
Innovation Solution
A reduced-complexity weld training system using a computing device with a processor, display device, and input device that allows users to design weld procedures, simulate setting up a welding environment, and perform virtual welding operations, providing real-time feedback and visualization of the welding process without the need for physical equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional weld training systems use precise sensor suites and positioning requirements, then tracking accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual copy of the welding environment and process through software simulation, eliminating the need for complex physical sensor suites and positioning systems. The virtual welding environment replicates all necessary tracking and measurement functions through computer-generated models, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent replaces mechanical positioning systems and physical sensors with software-based tracking and virtual reality technologies. The mechanical complexity of precise positioning requirements is substituted with computational methods that track welder performance through software algorithms rather than physical measurement devices.
2Reliability
If conventional weld training systems provide realistic physical welding environments, then training realism is improved, but cost and device complexity increase
Solution Approach 1:
The patent creates a virtual replica of the welding environment that encompasses all aspects of realistic welding training including equipment operation, safety procedures, and welding techniques. This virtual copy provides complete training realism without requiring expensive physical welding equipment, facilities, and safety infrastructure.
Solution Approach 2:
The virtual welding environment serves multiple training functions simultaneously - it can simulate various welding positions, materials, equipment configurations, and safety scenarios within a single system. This multi-functionality replaces the need for multiple specialized physical training setups, reducing overall system complexity while maintaining comprehensive training realism.
3Device complexity
If conventional weld training systems use reduced complexity approaches, then cost is reduced, but ability to simulate realistic welding environments deteriorates
Solution Approach 1:
The patent transitions from physical three-dimensional welding environments to a virtual three-dimensional space rendered through computer graphics and display technologies. This dimensional transformation allows the system to maintain complete welding environment realism while using software-based solutions instead of expensive physical equipment, achieving reduced complexity without sacrificing simulation fidelity.
4Adaptability or versatility
If conventional weld training systems provide comprehensive physical equipment, then training completeness is improved, but cost and setup time increase
Solution Approach 1:
The patent pre-programs all welding procedures, equipment configurations, safety protocols, and training scenarios into the virtual system before training begins. This preliminary preparation eliminates the need for physical equipment setup, assembly, and configuration during training sessions, reducing setup time to minimal while maintaining complete training versatility.
Data Source
AI summary
An example weld training system includes a display device; an input device; a processor; and machine readable instructions cause the processor to demonstrate to a user an effect of a combination of welding-related variables by: enabling the user to design a weld procedure using the input device by selecting weld parameters including weld current and weld voltage; simulating a welding operation on a simulated workpiece using the selected weld parameters in a welding model and a simulated physical welding environment to determine a modeled result of the welding operation; displaying a simulation animation of the welding operation on the display device according to the simulation; displaying the modeled result of the weld on the display device using at least one of an image of a surface of a weld bead or a cross-section of the weld bead and the simulated workpiece; and displaying information about an anomaly present in the weld determined based on the simulation, the information about the anomaly comprising at least one of a cause of the anomaly, a suggested change in one or more of the welding-related variables to avoid the anomaly, or a location of the anomaly in the image of the weld bead or in the cross-section of the weld bead.