Welding Workpiece Marking for Camera-Based Joint Detection
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Solution Overview
Problem
Current welding training systems are expensive and often inadequate in training operators to perform high-quality welds, limiting their effectiveness in preparing operators for industrial applications.
Innovation Solution
A comprehensive welding system that integrates sensing devices, software, and hardware to monitor and manage welding data, provide virtual reality training, and offer real-time feedback, enabling operators to practice and improve their welding skills through augmented and virtual reality modes, as well as physical training with precise data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding training systems are used, then operators can receive training, but the cost is high and training quality is inadequate
Solution Approach 1:
The patent uses visual markers and image capture to create a digital representation of the welding workpiece and training environment. The system captures images of the workpiece with markers, processes them to determine joint shapes and welding parameters, and uses this digital model for training without requiring expensive physical training equipment. This copying approach allows operators to train on virtual representations, reducing the need for costly physical training systems while maintaining training quality.
2Ease of operation
If physical welding training systems are used, then operators can practice welding, but the systems are expensive to acquire and operate
Solution Approach 1:
The patent replaces complex mechanical welding training systems with an optical and computational system. Instead of using expensive physical training rigs, mechanical welding equipment, and extensive instructor time, the system uses markers, cameras, image processing algorithms, and software to provide automated training. This substitution of mechanical systems with optical and computational approaches significantly reduces acquisition and operational costs while improving accessibility.
3Manufacturing precision
If comprehensive welding monitoring and data management systems are implemented, then welding quality can be improved, but system complexity increases
Solution Approach 1:
The patent creates a multi-functional system where a single integrated platform performs multiple welding-related functions: visual marker detection, joint shape determination, welding parameter calculation, real-time monitoring, data management, and training. By consolidating these functions into one universal system rather than separate specialized systems, the patent reduces overall system complexity while maintaining high welding quality through comprehensive monitoring and data management.
Data Source
AI summary
An embodiment of a system includes a marking tool configured to apply one or more markers on a first surface of a workpiece for a live welding session. The one or more markers have known geometric properties that may facilitate determination of the first surface and a weld joint. An embodiment of a method includes applying a first set of one or more markers to a first surface of a workpiece, detecting the applied first set of one or more markers with a camera, and determining, via processing circuitry coupled to the camera, at least one of the first surface of the workpiece and a weld joint based at least in part on the detected first set of one or more markers.