Weld Monitoring That Identifies Job and Part Without Operator Input
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Solution Overview
Problem
Conventional weld monitoring systems rely on operator input, which can be inconsistent due to operator forgetfulness or preoccupation, leading to ineffective monitoring.
Innovation Solution
The implementation of a weld monitoring system that automatically tracks the position and orientation of both the operator and the welding tool, enabling the system to identify the job, part, and activity involved, even without operator input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If operator input is used to monitor welding operations, then the monitoring system can capture operational details, but the reliability of monitoring deteriorates due to operator forgetfulness and preoccupation
Solution Approach 1:
The system enables self-service monitoring by automatically capturing welding operation data through sensors and tracking devices without requiring operator input. The monitoring system serves itself by autonomously collecting, processing, and storing welding parameters, operator position, and tool position data, eliminating the reliability issues associated with manual operator reporting.
Solution Approach 2:
The patent replaces the mechanical system of manual operator input with an automated electronic monitoring system. Sensors, GPS trackers, and data processing circuits substitute for human operators in capturing and reporting welding information, thereby improving reliability by eliminating human factors such as forgetfulness and preoccupation.
2Reliability
If automated tracking of operator and tool position is implemented, then monitoring effectiveness is improved, but device complexity increases
Solution Approach 1:
The system achieves multi-functionality by integrating multiple monitoring capabilities into a single unified platform. The tracking system simultaneously monitors operator position, tool position, welding parameters, and generates reports, eliminating the need for separate systems and reducing overall complexity despite the advanced functionalities provided.
Solution Approach 2:
The patent introduces an intermediary data processing system that acts as a mediator between various sensors and the central monitoring platform. This intermediary layer standardizes data collection from multiple sources (GPS trackers, sensors, circuits) and presents unified information to the monitoring system, simplifying integration and reducing complexity.
3Productivity
If continuous automated monitoring is implemented, then productivity is improved through better quality assurance and maintenance analysis, but energy consumption increases
Solution Approach 1:
The system implements periodic data collection and transmission rather than continuous monitoring at maximum capacity. Sensors and trackers operate in periodic cycles, collecting data at intervals and transmitting information batch-wise, which maintains monitoring effectiveness for productivity improvement while significantly reducing energy consumption compared to continuous high-frequency monitoring.
Data Source
AI summary
In some examples, weld monitoring systems may automatically identify a job, part, and/or activity in which an operator and/or tool is involved based on a tracked position and/or orientation of the operator and/or tool. The monitoring and/or recording of job, part, and/or activity information for each operator and/or tool may facilitate productivity, quality assurance, and/or maintenance analysis, as well as future planning. The automatic identification of the job, part, and/or activity in which the operator and/or tool is involved also ensures that that the weld monitoring system can still monitor effectively even if operators neglect to provide input regarding their activities.