Calibration Tool for Welding Torch Position Tracking
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Solution Overview
Problem
Current welding training systems are expensive and often inadequate for training welding operators to perform high-quality welds, limiting their effectiveness in preparing operators for industrial applications.
Innovation Solution
A welding system that includes a calibration tool and method for calibrating the position and orientation of welding equipment, using markers and sensors to track the welding torch and workpiece, and providing real-time feedback through a user interface, enabling precise control and data analysis for improved training outcomes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive welding training systems are acquired, then training quality may be improved, but cost increases significantly
Solution Approach 1:
The patent creates a calibration tool that replicates the geometry and positioning requirements of actual welding workpieces. By using markers and sensors to track the welding torch position relative to calibrated reference points, the system provides accurate training feedback without requiring expensive industrial welding equipment. The calibration process establishes a virtual model of the welding environment that can be used for training purposes.
Solution Approach 2:
The patent replaces complex mechanical welding measurement systems with an optical/electronic tracking system. Instead of using expensive mechanical fixtures and measurement devices, the system uses markers with visual features that can be detected by cameras or sensors, providing precise position and orientation data through image processing and coordinate transformation algorithms.
2Ease of operation
If manual welding training is provided, then operator skill development is achieved, but measurement precision of welding parameters is insufficient
Solution Approach 1:
The patent implements a feedback system that provides real-time information to the trainee about welding torch position, orientation, and movement. The sensors detect marker positions and the system calculates torch coordinates, then provides feedback through the user interface about whether the torch is in the correct position and orientation. This immediate feedback enables operators to learn and improve their skills while maintaining precise measurement of welding parameters.
Solution Approach 2:
The patent introduces markers as intermediary objects between the welding torch and the measurement system. These markers with visual features serve as reference points that enable precise measurement of torch position and orientation without requiring direct measurement of the torch itself. The markers act as mediators that translate physical torch position into measurable visual data that can be processed by the system.
3Loss of time
If welding equipment position and orientation are not calibrated, then training can proceed without setup time, but manufacturing precision of weld quality is compromised
Solution Approach 1:
The patent performs calibration as a preliminary action before training begins. The system calibrates the welding equipment by establishing the relationship between the physical welding torch position and the virtual training environment coordinates. This preliminary calibration ensures that subsequent training sessions can proceed with accurate position and orientation measurement, maintaining weld quality precision without requiring repeated calibration during training.
Solution Approach 2:
The patent changes the coordinate system parameters to align the virtual training environment with the physical welding equipment. By transforming coordinates between the camera/sensor reference frame and the welding workpiece reference frame, the system ensures that position and orientation measurements are accurate. This parameter transformation enables precise measurement of welding parameters while maintaining efficient training operations.
Data Source
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Figure 2A~3
AI summary
A calibration tool includes a calibration tip. The calibration tool may be for a welding training system or some other welding system. The calibration tool also includes a first marker disposed a first distance from the calibration tip and a second marker disposed a second distance from the first marker. The second distance is adjustable during calibration.