Welding Torch Marker Layout for Reliable Pose Tracking
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Solution Overview
Problem
Current welding training systems are expensive and often inadequate in training operators to perform high-quality welds, leading to limited availability and effectiveness in preparing operators for manual welding operations.
Innovation Solution
A welding system that includes a welding torch with visual markers for tracking, sensing devices for monitoring the weld environment, and software for data management and training modes such as virtual reality and augmented reality, integrated with a user interface for real-time feedback and data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional welding training systems are used, then operators can be trained for manual welding operations, but the systems are expensive and have limited availability
Solution Approach 1:
The patent creates a virtual copy of the welding environment using computer-generated imagery and virtual reality technology. This allows operators to train in a realistic welding simulation without requiring expensive physical welding equipment and materials, thereby reducing training system costs while maintaining training quality through immersive virtual experiences
Solution Approach 2:
The welding training system integrates multiple training modes (virtual reality, augmented reality, and traditional instruction) into a single platform that can adapt to different learning styles and skill levels. This multi-functional approach eliminates the need for separate expensive training systems for each method, making high-quality training more accessible and affordable
2Manufacturing precision
If traditional welding training systems are used, then operators can be trained, but the training is often inadequate for performing high-quality welds
Solution Approach 1:
The system incorporates real-time feedback mechanisms where the virtual reality environment monitors welding parameters, technique, and performance metrics, providing immediate corrective guidance to operators. This feedback loop ensures operators learn proper techniques for high-quality welds without requiring complex manual evaluation systems
Solution Approach 2:
The training system pre-programs correct welding techniques, parameters, and procedures into the virtual environment before training begins. Operators learn by practicing these pre-established best practices in a risk-free virtual setting, ensuring they acquire skills for high-quality welds without needing complex real-time intervention systems
3Measurement precision
If multiple sensing devices are added for real-time monitoring, then training quality improves, but system complexity increases
Solution Approach 1:
The system replaces physical sensing devices with software-based detection algorithms that run within the virtual reality environment. These virtual sensors can monitor multiple welding parameters simultaneously without adding physical complexity to the training setup, achieving precise measurement through computational methods rather than additional hardware
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides cost-effective and comprehensive training, enabling operators to perform high-quality welds by integrating real-time monitoring and feedback, improving training efficiency and quality.
Implementation Method 1
Each LED is configured to emit light in a selected direction away from the welding device
Data Source
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Figure 2
Figure 2A~3
AI summary
A system includes a welding device (14), one or more cameras, and a controller coupled to the one or more cameras. The welding device includes a first set of visual markers (474) (474) oriented in a first direction and a second set of visual markers (474) (474) oriented in a second direction. Each set of visual markers (474) includes at least three visual markers (474). The one or more cameras are configured to observe the first set of visual markers (474) (474) when the first direction is directed toward the one or more cameras, and to observe the second set of visual markers (474) when the second direction is directed toward the one or more cameras. The controller is configured to track a position and an orientation of the welding device (149 based at least in part on detection of a threshold quantity of the first set of visual markers (474) or the threshold quantity of the second set of visual markers (474).