Weld Location Monitoring With Virtual Guidance for Correct Weld Order
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding systems face challenges in ensuring accurate placement and sequence of welds, especially in simulated or resistant materials, which can lead to warpage and distortion due to the inability to mark welding locations effectively.
Innovation Solution
A welding system that utilizes processing circuitry and cameras to monitor weld locations and order, providing real-time feedback and guidance through a display screen, and allows for virtual marking of workpieces to ensure correct weld placement and sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional marking methods (pen, marker) are used to mark welding locations, then operators can be guided during welding, but this approach is not possible for simulated welding operations or for welding operations where the workpieces are resistant to conventional markings
Solution Approach 1:
The patent uses digital images or 3D models of the workpiece as a virtual copy to display welding locations and sequences. Instead of physically marking the actual workpiece, the system creates a digital representation and overlays welding guidance information on this copy, which can be viewed on a display device or through augmented reality. This resolves the contradiction by eliminating the need for physical markings while providing the same guidance function.
Solution Approach 2:
The patent replaces the mechanical marking system (pens, markers physically touching the workpiece) with an optical/digital display system. Cameras capture images of the workpiece, processing circuitry identifies welding locations, and a display device presents the welding sequence information. This substitution enables welding guidance for simulated operations and resistant materials where mechanical marking is impossible.
2Ease of operation
If welding locations are marked on actual workpiece by operator, then welding guidance is provided, but this requires manual intervention and is time-consuming
Solution Approach 1:
The system enables self-service welding guidance by automatically capturing workpiece images, processing them to identify welding locations and sequences, and displaying the guidance information without requiring operator intervention for marking. The workpiece itself serves as the reference for the camera to capture and process, eliminating the need for manual marking operations.
Solution Approach 2:
The system performs preliminary action by pre-identifying and displaying all welding locations and sequences before the welding operation begins. The digital model or processed images show the complete welding sequence in advance, allowing operators to understand the required sequence without time-consuming step-by-step marking during the actual welding process.
3Manufacturing precision
If welding out of sequence or at incorrect locations occurs, then quality issues arise (warpage, distortion), but conventional systems lack real-time monitoring capability
Solution Approach 1:
The system provides feedback by displaying the current welding sequence status and comparing it against the required sequence. The processing circuitry monitors which welds have been completed and highlights the next required welding location, providing continuous feedback to the operator. This real-time information feedback prevents welding out of sequence by clearly indicating the correct next step.
Solution Approach 2:
The system introduces an intermediary information layer between the workpiece and the operator. Instead of directly observing the physical workpiece, the operator views a digital representation or augmented reality overlay that provides intermediate information about welding locations, sequences, and completion status. This intermediary layer preserves and communicates critical sequence information that would otherwise be lost.
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, etc.