Welding Torch Feedback Display for Real-Time Weld Training
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Solution Overview
Problem
Welding training systems are often expensive and inadequate in training operators to perform high-quality welds, with limited availability and ineffective training methods.
Innovation Solution
A welding system that provides real-time feedback to operators through a welding torch display, using sensors and control circuitry to monitor and adjust parameters such as position, orientation, and movement, and includes features like vibration feedback and augmented reality training modes to enhance welding technique.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding training systems are used, then welding operators can be trained, but the systems are expensive and inadequate in training operators to perform high quality welds
Solution Approach 1:
The patent implements real-time feedback mechanisms through displays on the welding torch that show welding parameters (travel speed, angle, distance) and provide corrective guidance to operators. This feedback loop enables operators to immediately adjust their technique to achieve high-quality welds, directly resolving the contradiction by making the training system effective without requiring excessive complexity
Solution Approach 2:
The patent replaces complex mechanical training apparatus with electronic sensors, processors, and display systems that automatically measure and evaluate welding parameters. This substitution reduces the mechanical complexity of the training system while improving weld quality through precise digital measurement and real-time feedback
2Ease of operation
If welding training systems are acquired, then operators can be trained, but the systems are expensive with limited availability
Solution Approach 1:
The patent integrates multiple training functions into a single welding torch system that can operate in both training mode and production mode. The same torch with integrated sensors and displays serves dual purposes, making the system more accessible and cost-effective by eliminating the need for separate dedicated training equipment
Solution Approach 2:
The welding torch system automatically measures welding parameters using integrated sensors and provides self-evaluation through displays and audio feedback. This self-service capability eliminates the need for expensive instructor oversight and complex evaluation apparatus, improving accessibility while reducing system cost
3Manufacturing precision
If real-time feedback is provided through welding torch display, then operator proficiency and weld quality improve, but the device complexity increases
Solution Approach 1:
The patent merges the display, sensors, and control electronics directly into the welding torch itself rather than using separate external devices. This integration consolidates multiple components into a single unified tool, improving weld quality through real-time feedback while minimizing the increase in overall system complexity
Data Source
AI summary
A method includes displaying, on a display of a welding torch, a welding parameter in relation to a predetermined threshold range for the welding parameter, a target value for the welding parameter, or some combination thereof as a position of the welding torch changes, an orientation of the welding torch changes, a movement of the welding torch changes, or some combination thereof, to enable a welding operator to perform a welding operation with the welding parameter within the predetermined threshold range, at the target value, or some combination thereof. The welding parameter is associated with the position of the welding torch, the orientation of the welding torch, the movement of the welding torch, or some combination thereof.