Welding Tool Orientation Monitoring for Sloped Joint Calibration
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Solution Overview
Problem
Conventional welding technique monitoring systems struggle to accurately assess welding technique on sloped workpieces, often requiring multiple calibration steps and assuming joints are either horizontal or vertical, which limits their robustness and ease of use.
Innovation Solution
A welding technique monitoring system that uses two calibration steps or a fluid calibrating movement to monitor welding technique along any sloped straight welding joint, employing a sensor system with inertial measurement units to track tool orientation and provide feedback on welding technique parameters, including work and travel angles, regardless of the joint's slope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding monitoring systems assume joints are horizontal or vertical, then calibration is simplified, but the system cannot accurately monitor welding technique on sloped workpieces
Solution Approach 1:
The system changes the reference frame parameters by introducing a gravity vector and calculating a transformed coordinate system that accounts for workpiece slope. The monitoring system adapts to any slope angle by transforming the sensor data into a reference frame where the workpiece appears horizontal, allowing conventional monitoring algorithms to work correctly on sloped surfaces without manual recalibration for each slope angle
Solution Approach 2:
The calibration system achieves universality by using a single calibration procedure that works for any workpiece slope from 0 to 360 degrees. The gravity-based reference frame transformation makes the system multi-functional, capable of monitoring welding technique on horizontal, vertical, and any intermediate sloped joints using the same calibration approach
2Measurement precision
If multiple calibration steps are used to accommodate sloped workpieces, then measurement accuracy improves, but calibration time and complexity increase
Solution Approach 1:
The system performs preliminary action by establishing a gravity-based reference frame during a single calibration step before welding begins. The gravity vector is captured once during calibration, and this reference frame is then used throughout the welding process to accurately monitor technique on any slope, eliminating the need for repeated calibration steps during welding operations
Solution Approach 2:
The system replaces complex mechanical calibration procedures with a gravity-based computational approach. Instead of using multiple physical calibration steps or mechanical adjustments for different slopes, the system uses inertial sensors to detect the gravity vector and computationally transforms the coordinate system, substituting mechanical complexity with sensor-based detection and mathematical transformation
3Productivity
If a single calibration step is used assuming horizontal or vertical joints, then calibration is fast and simple, but the system fails to accurately monitor welding on sloped workpieces
Solution Approach 1:
The system changes the reference frame parameters by introducing a gravity vector and calculating a transformed coordinate system that accounts for workpiece slope. The monitoring system adapts to any slope angle by transforming the sensor data into a reference frame where the workpiece appears horizontal, allowing conventional monitoring algorithms to work correctly on sloped surfaces without manual recalibration for each slope angle
Solution Approach 2:
The system replaces complex mechanical calibration procedures with a gravity-based computational approach. Instead of using multiple physical calibration steps or mechanical adjustments for different slopes, the system uses inertial sensors to detect the gravity vector and computationally transforms the coordinate system, substituting mechanical complexity with sensor-based detection and mathematical transformation
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 robust, fast, and straightforward calibration, enabling accurate monitoring of welding technique on slopes from 0 to 360 degrees, enhancing the quality of welds by offering real-time feedback on tool orientation and movement.
Implementation Method 1
employing a sensor system with inertial measurement units to track tool orientation
Implementation Method 2
determining a gravity vector
Data Source
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Figure 2a~2b
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AI summary
Described herein are examples of tool based welding technique monitoring systems with sloped workpiece calibrations. Using two calibration steps (or one fluid calibrating movement), the disclosed system is able to monitor welding technique along a straight welding joint of any slope, be the slope 0/180/360 degrees (i.e., horizontal), 90/270 degrees (i.e., vertical), or any slope in between. The system provides an inexpensive, intuitive, and relatively robust way of tracking an orientation of a welding-type tool in relation to a welding joint and/or workpiece, and providing welding technique feedback based on the relationship.