Weld Position Tracking for Automatic Part Identification

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Solution Overview

Problem

Weld monitoring systems often rely on operator input, which can be inconsistent or absent, leading to ineffective monitoring and potential errors in welding operations.

Innovation Solution

A weld monitoring system that automatically tracks the position and orientation of operators and tools, identifies the job and part being worked on, and provides appropriate welding instructions and equipment configuration, reducing the need for operator input.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If operator input is used for weld monitoring, then the system can obtain welding operation data, but the monitoring effectiveness deteriorates due to operator preoccupation and forgetfulness

Engineering Contradiction:

Improvewelding operation dataVSAvoidmonitoring effectiveness

Core Design Contradiction:

Loss of informationVSReliability

Solution Approach 1:

The system enables automatic monitoring by having the welding equipment itself report operational data to the monitoring system, eliminating the need for operator input. The welding power source automatically transmits welding parameters and operational status, allowing the system to self-monitor without human intervention.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical process of operator input with an automated electronic data transmission system. The welding power source electronically communicates welding parameters directly to the monitoring system, substituting human observation and reporting with automated sensor and communication systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If automated tracking is implemented, then monitoring reliability improves, but device complexity increases

Engineering Contradiction:

Improvemonitoring effectivenessVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The welding power source performs multiple functions: it provides welding power, tracks welding parameters, and communicates operational data to the monitoring system. By making the power source multi-functional, the system avoids adding separate tracking devices, thereby reducing overall system complexity while maintaining automated monitoring capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the monitoring functionality with the existing welding power source system. The tracking system is integrated into the power source rather than being a separate entity, merging data collection and communication functions with the welding control system to reduce the number of discrete components.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250205802A1Weld monitoring systems with job and part position tracking

Publication Date: 2025.06.26 ILLINOIS TOOL WORKS INC

AI summary

In some examples, weld monitoring systems automatically identify a job and/or part on which an operator and/or tool is work based on a tracked position and/or orientation of an operator and/or tool. The weld monitoring systems may automatically provide appropriate welding instructions to the operator based on the identified job and/or part. The weld monitoring systems may also identify appropriate equipment and/or devices for the identified job and/or part, and/or configure the equipment and/or devices appropriately for the identified job and/or part.