Mixed-Reality Welding Training With IR Marker Tracking
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Solution Overview
Problem
Existing welding training assemblies using RGB cameras for object recognition and tracking have limited tracking range, require maintaining a minimum distance from the workpiece, and are sensitive to lighting conditions, leading to restricted applicability and potential dizziness from wide-angle lenses.
Innovation Solution
A welding training assembly utilizing IR-reflecting reference markers on the workpiece and welding torch, combined with an IR camera and mixed-reality headset, enabling larger tracking ranges and precise object recognition and tracking, allowing closer proximity and dynamic movements without the limitations of RGB cameras.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If RGB cameras are used for object recognition and tracking, then the system can capture the field of vision of the manual welder, but the tracking range is limited and the manual welder must maintain a minimum distance from the workpiece
Solution Approach 1:
The patent introduces an IR camera as an intermediary device that captures IR images of IR-reflecting reference markers. This intermediary system allows tracking to occur outside the RGB camera's field of vision, enabling the manual welder to approach the workpiece closely without tracking limitations. The IR camera acts as a mediator that extends the tracking capability beyond the visual field constraints of the RGB camera.
Solution Approach 2:
The patent changes the operational parameter from visible light (RGB camera) to infrared reflection (IR camera). By using IR-reflecting reference markers and an IR camera with a larger field of vision, the system overcomes the distance and angle limitations of RGB cameras. This parameter change enables tracking in a broader spatial range and allows the manual welder to work at closer distances to the workpiece.
2Area of stationary object
If wide-angle lenses are used to expand the field of vision, then the tracking range increases, but the manual welder experiences dizziness
Solution Approach 1:
The IR camera serves as an intermediary that captures reference marker positions without requiring the manual welder to view through wide-angle lenses. The IR images are processed to determine spatial positions, providing an expanded field of vision effect without the harmful visual distortion that causes dizziness. The intermediary system separates the tracking function from the visual display function.
Solution Approach 2:
The patent replaces the mechanical/optical wide-angle lens approach with an infrared-based tracking system. Instead of using wide-angle lenses that cause dizziness when viewed directly, the system uses an IR camera to capture reference markers and computationally determines spatial positions. This substitution eliminates the harmful visual effects while achieving the goal of expanded tracking range.
3Reliability
If RGB cameras are used for tracking, then the system can capture visual information, but the tracking is sensitive to lighting conditions
Solution Approach 1:
The patent changes the detection parameter from visible light intensity (RGB camera) to IR reflection properties. The IR-reflecting reference markers are designed to reflect infrared radiation, and the IR camera captures these reflections independently of ambient lighting conditions. This parameter change makes the tracking system reliable across various lighting environments, as IR reflection is not affected by visible light variations.
Solution Approach 2:
The IR-reflecting reference markers create an inert tracking environment that is immune to lighting condition variations. By using infrared reflection rather than visible light capture, the system establishes a tracking mechanism that operates reliably regardless of ambient lighting. The IR reference markers effectively create a stable, lighting-independent reference system for accurate tracking.
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
Ensures precise and reliable tracking of the welding torch and workpiece, even in dynamic scenarios, with increased tracking range and reduced hardware requirements, enhancing training realism and safety.
Implementation Method 1
a first plurality of IR-reflecting reference markers 71 are provided on the training workpiece 4, which are arranged on the training workpiece 4 in a first reference pattern 72 individualizing the training workpiece 4
Data Source
AI summary
A welding training assembly including a mixed-reality headset having an RGB camera and an IR camera, in which The IR field of vision is greater than the RGB field of vision. IR-reflecting reference markers, which are arranged on a training workpiece and on a training manual welding torch in a reference pattern that individualizes the training workpiece and the training manual welding torch, are sensed by the IR camera for object recognition and object tracking.