Welding Positioning Stand With Orientation Sensing Feedback
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Solution Overview
Problem
It can be difficult for less experienced human operators to accurately judge whether their welding technique is good or bad, which can negatively impact the quality of welds.
Innovation Solution
A portable welding technique monitoring system that includes a positioning stand with an adjustment mechanism, a workpiece holder, an orientation sensor, and processing circuitry to determine and adjust the workpiece orientation, using inertial measurement units and mobile devices to provide guidance on proper positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If portable monitoring systems are used, then ease of operation and portability are improved, but measurement precision and reliability may be compromised
Solution Approach 1:
The patent replaces traditional mechanical orientation measurement devices with electronic sensors (accelerometers, gyroscopes, magnetometers) integrated into mobile devices. This substitution enables portable monitoring while maintaining measurement precision through digital sensing capabilities that are less susceptible to mechanical wear and alignment errors.
Solution Approach 2:
The patent introduces processing circuitry as an intermediary between the sensors and the user interface. This intermediary component processes raw sensor data to calculate workpiece orientation angles, compensates for sensor errors, and provides guidance feedback to operators, thereby ensuring measurement accuracy despite the portable nature of the system.
2Manufacturing precision
If real-time feedback systems are implemented, then welding quality is improved, but device complexity increases
Solution Approach 1:
The patent utilizes mobile devices (smartphones, tablets) that operators already possess, leveraging their existing sensors, processing power, and display capabilities. This multi-functional approach provides real-time feedback without requiring a dedicated complex monitoring system, thereby improving weld quality while minimizing additional device complexity.
Solution Approach 2:
The system uses the mobile device's own built-in sensors (accelerometer, gyroscope, magnetometer) to perform orientation measurements and calculations. The device serves itself by utilizing its inherent capabilities rather than requiring external specialized equipment, thus providing real-time feedback while keeping the system relatively simple.
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 effectively assists operators in achieving proper workpiece orientation, enhancing weld quality by providing real-time feedback and guidance, making it suitable for both training and production scenarios.
Implementation Method 1
an orientation sensor configured for connection to the positioning stand such that a sensor orientation of the orientation sensor will change when the positioning stand orientation changes, the orientation sensor being configured to capture orientation sensor data relating to the positioning stand orientation
Implementation Method 2
the orientation sensor being configured to capture orientation sensor data relating to the positioning stand orientation
Data Source
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AI summary
The present application relates to a welding-type system (100) with a stand (102) comprising portable technique systems for monitoring the technique of operators during a welding-type operation, and/or providing technique feedback. In some examples, the portable technique monitoring system is designed to work with a mobile device that is highly portable. The portable technique monitoring system can also work with standard and/or common workpieces, tools, and/or equipment. The few custom components that are required for the portable technique monitoring system are lightweight, and highly portable, as is the system itself, making it a very attractive solution for technique monitoring in both training and production scenarios.