Welding Tool Orientation Feedback With Fast Calibration Setup
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Solution Overview
Problem
Conventional welding technique monitoring systems are ineffective in accurately assessing the quality of welding techniques, particularly for less experienced operators, as they require complex calibration and additional sensors, making it difficult to provide real-time feedback on parameters like work angle, travel angle, and travel speed.
Innovation Solution
A tool-based welding technique monitoring system that uses a sensor module attached to the welding tool to track its orientation and provide real-time feedback on welding technique parameters, requiring minimal calibration and no additional sensors, with the system being portable and inexpensive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional welding technique monitoring systems are used, then measurement of welding parameters is possible, but device complexity increases and ease of operation deteriorates due to complex calibration requirements and additional sensors
Solution Approach 1:
The patent extracts the essential monitoring function from complex conventional systems by using only the welding tool's existing sensors (accelerometer, gyroscope, magnetometer) to determine orientation and technique parameters. This eliminates the need for additional external sensors and complex calibration systems while maintaining measurement capability.
Solution Approach 2:
The system leverages the welding tool's own built-in sensors to perform self-monitoring of technique parameters. The tool serves itself by using its existing inertial measurement unit to track orientation, movement, and positioning without requiring external monitoring equipment or complex setup procedures.
2Measurement precision
If conventional welding technique monitoring systems are used, then welding parameters can be monitored, but ease of operation worsens due to difficult calibration and setup procedures
Solution Approach 1:
The system automatically utilizes the welding tool's existing sensor data without requiring manual calibration procedures. The inertial measurement unit continuously provides orientation and movement data that is processed to determine technique parameters, eliminating the need for operators to perform complex calibration steps.
Solution Approach 2:
The system changes the approach from manual calibration of multiple sensors to automatic determination of technique parameters through mathematical processing of existing sensor data. This transforms the operation from a calibration-intensive process to a simple data processing task that occurs automatically during welding.
3Measurement precision
If additional sensors are added to monitoring systems, then measurement precision improves, but device complexity and cost increase
Solution Approach 1:
The patent extracts the monitoring capability from the welding tool itself rather than adding external sensors. By utilizing the already-present inertial measurement unit in the welding tool, the system achieves technique parameter measurement without requiring any additional sensors or monitoring equipment.
Solution Approach 2:
The welding tool's inertial measurement unit serves multiple functions: it provides data for both weld quality monitoring and technique parameter assessment. This multi-functional use of existing sensors eliminates the need for dedicated monitoring sensors while maintaining measurement precision.
Data Source
AI summary
Described herein are examples of tool based welding technique monitoring systems that provide an inexpensive, intuitive, and relatively robust way of tracking an orientation of a welding-type tool, and providing welding technique feedback based on the orientation. The system requires no sensors apart from a simple and/or relatively inexpensive sensor module that can travel with the welding-type tool, which makes the system highly portable. The system can also provide some feedback with minimal calibration, which can be valuable in situations where an operator forgets, or is unwilling, to take the time to fully calibrate the system. Additionally, full calibration of the system can be accomplished with a fast, simple, intuitive calibration technique.