Welding Tool Orientation Calibration for Sloped Joint Monitoring
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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 on any sloped straight welding joint, employing a sensor system integrated with the welding tool to track tool orientation and provide feedback on slope and travel direction, utilizing inertial measurement units and magnetometers for precise orientation tracking.
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 calibration process is divided into two distinct steps: first calibrating the sensor system on a horizontal surface to establish a baseline reference frame, then calibrating on a vertical surface to define the joint orientation. This segmentation allows the system to handle arbitrary slopes by combining references from both horizontal and vertical calibrations, resolving the contradiction between calibration simplicity and slope compatibility.
Solution Approach 2:
The system transitions from assuming a single-dimensional orientation (horizontal or vertical only) to a three-dimensional orientation system that can represent any slope angle. By using IMU sensors to capture pitch, roll, and yaw angles, the system creates a comprehensive spatial reference frame that accommodates workpieces at any orientation, thereby achieving versatility without sacrificing calibration ease.
2Measurement precision
If multiple calibration steps are required for sloped workpieces, then measurement accuracy improves, but calibration time and complexity increase
Solution Approach 1:
The system performs preliminary calibration on horizontal and vertical surfaces before actual welding operations. By establishing the reference frame in advance through these two standardized positions, the system prepares all necessary orientation data beforehand, enabling accurate monitoring of sloped workpieces during welding without requiring additional calibration time during production.
Solution Approach 2:
The patent replaces complex mechanical multi-step calibration procedures with an electronic sensor-based system. The IMU sensors automatically capture orientation data and the processing circuitry computationally determines the reference frame, substituting manual mechanical alignment with automated electronic measurement. This reduces calibration time while maintaining precision through mathematical calculations rather than physical adjustments.
3Productivity
If a single calibration step is used, then calibration speed increases, but the system relies on restrictive assumptions about joint orientation
Solution Approach 1:
The two-step calibration process creates a universal reference frame that can serve multiple functions: it accurately defines horizontal orientations, vertical orientations, and any intermediate slope angles. This multi-functional reference frame eliminates the need for different calibration procedures for different workpiece orientations, achieving both speed and robustness by making the system universally applicable to all slope configurations.
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 joints of any slope, enhancing the quality of welds by offering real-time feedback to operators, thus improving welding efficiency and consistency.
Implementation Method 1
determining a joint parallel plane or joint perpendicular vector based on sensor data detected during a first time period by an inertial measurement unit
Implementation Method 2
employing a sensor system integrated with the welding tool to track tool orientation and provide feedback on slope and travel direction, utilizing inertial measurement units and magnetometers for precise orientation tracking
Data Source
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.